INSTALLATION MANUAL APPLICATION: FA C09 095G (95gph @ 10psi) FA C09 150G (150gph @ 10psi) Duramax 2500 & 3500 2001-2014
Dear Valued Customer, “Made in the USA” is not just a slogan at FASS; it’s what we live by! FASS is not only assembled in the USA but 98%+ of the FASS product is manufactured in the USA, helping to employ Americans and strengthen America. At FASS, we scrutinize our suppliers and demand the highest quality American-made components. However, this does come at a price, which is one of the main reasons FASS products are more expensive than the competition.
¡WARNINGS! Read all instructions before starting installation of this product! Installing the improper FASS Pump can cause severe engine damage. FASS Recommended Application FA C09 095G GM Duramax 2001-2015 with stock - moderate horsepower modifications FA C09 150G GM Duramax 2001-2015 with moderate - extreme horsepower modifications Note: Due to the increase of fuel flow you may encounter a problem with the stock fuel module. Adding a FASS suction tube kit will solve that issue.
INSTALLATION MANUAL Follow these steps to ensure a simple installation of your new FASS ADJUSTABLE FUEL PUMP 1. Read the installation manual completely before attempting installation. The installation of this product indicates that the buyer has read and understands the limitations of the FASS manufacturers warranty agreement and accepts the responsibility of its terms and conditions. 2. Inventory the package components. Notify the place of purchase immediately of any parts missing or damaged. 3.
Adjustable Fuel Pump Series 95 or 150 GPH 10 PSI (Approximately) A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage! Adjustment Lock Nut Set screw Boost Compensation Port ‘T’ Fuel Inlet Port “E” To Engine Fuel Pressure Port Installation Step 1: Step 2: Step 3: Step 4: Step 5: Step 6: Install Electrical Harness Prepare Suction & Return Lines Mount Fuel System Install Fuel Line Check/Set Pressure Check Installation
Contents THB-1001 FF-3248 BHB-1001 MP-9012 FPB-2005 FL-1002 x14’ WH-1006
Mounting Package Contents 46044 RS-1002 46260 PL-1005 10-300 PLB-1212 QD-1002 *Cable Ties* Ring Terminal HC-1001 1/4” washer 1/4” Nut RS-2001 4 1/4 - 20x1.75” 2 1/4 - 20x1.
The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes later in the installation. A. Using wire stripping tool remove excess insulation off the add-a-fuse and the WH-1006. B. Place 46044 with butt connector to the exposed wire from the WH-1006 into butt connector. Using crimping tool connect 46044 and WH-1006 with butt connector. Install 46260 to 46044 bottom slot (opening that is near the spade). C.
E. If fuse panel is located in the cab it will be necessary to guide the single red wire from the relay through the fire wall grommet to access the fuse panel. F. Locate fuse box under hood and select ignition hot fuse. Remove fuse and put Add-A-Fuse in place. Install fuse previously removed. The use of a corrosion preventative on electrical connections is recommended. G. Route WH-1006 wire harness along frame rail to mounting location of pump.
Some of the photo’s are of a different application, procedures are the same. A. If necessary, carefully bend the sheet metal down that is covering the side. B. This step can be omitted on 2011–Present models. Remove the 3 bolts holding the fuel cooler to the mounting bracket. The fuel cooler is located in front of the fuel tank. C. Using a fuel line disconnect tool, disconnect the factory suction line located above the fuel cooler.
Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly. E. Push the PLB-1212 into the factory suction line until you hear a click and the tabs are locked in place. 2001-2010 F. 2011-Present Using an HC-1001 hose clamp, insert the QD-1002 into the other end of the provided FL-1002 fuel line and secure. Loop this end over the frame to the factory steel fuel line disconnected in Step 2b.
A. Locate bed bolt and remove the bolt. Position RS-2001 between FPB-2005 and truck bed. B. Secure THB-1001 to bolt on bracket with the RS 1002 and the (2)– 1/4-20x1 bolts, 1/4 washers, and 1/4 nuts. With the (4)-1/4-20x1.75” bolts thread the BHB-1001 to the THB-1001. Note: Use of Anti-seize compound is highly recommended. C. Using thread tape, install the 2 10-300 into the “T” & “E” ports. Torque to 40 ft./lbs.
D. Slid the FASS pump into mounting brackets with the weep hole facing down. Torque (4) bolts to 110 inch pounds. VERY IMPORTANT: REMEMBERING THE POSITION OF THE “T” PORT, THERE IS A SMALL WEEP HOLE IN THE BASE DIRECTLY NEXT TO THE ELECTRIC MOTOR, THIS HOLE MUST AIM DIRECTLY TO THE GROUND!! IMPROPER INSTALLATION OF THE PUMP CAN CAUSE PREMATURE WEAR AND VOID MANUFACTURES WARRANTY.
Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly. A. Route suction line from Step 2e to port ‘T’. Cut FL-1002 to needed length. Using oil, insert PL-1005 and connect to 10-300 in port ’T’. Torque to 18 ft./lbs. Note: When installing Push-Lok fittings into fuel line, use oil on fittings and in the line. B. Install in-line fuel filter in an accessible location in the suction line using the HC-1001’s.
The preset pressure is approximately 10 psi. Follow these steps to check or reset the fuel pressure. The port with 1/8” Allen plug marked with the letter “P” is your fuel pressure port. Exceeding factory fuel pressure may result in severe engine damage. Consult with engine manufacture before adjusting pressure! With the pump running – Loosen the lock nut Turn the adjustment screw clock wise to increase pressure and counter clock wise to decrease pressure.
Disclaimer: To help insure you receive the proper system and customer support at the local level, FASS has a VIP and Authorized Dealer network representing FASS products. This is one reason you must purchase through a dealer to comply with our warranty policies. If you do not, there is no warranty! We recommend you go to www.FASSride.com, click “Find a Dealer”, put in their ZIP code, select the type of dealer, and see if the company you purchased from is listed.
