INSTALLATION MANUAL APPLICATION: FA C09 220G (220gph @ 10psi) Duramax 2500 & 3500 2001-2015
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 FA C09 220G Recommended Application Duramax 2001-2014 with super extreme horsepower modifications Secure vehicle from ROLLING! Use caution when drilling. Steer clear of any electrical wires , air lines or other damageable components.
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 220 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 InstallaStep 1: Install Electrical Harness Step 2: Prepare Suction & Return Lines Step 3: Mount Fuel System Step 4: Install Fuel Line Step 5: Check/Set Pressure
Contents THB-1001 FF-3248 BHB-1001 MP-9038 FPB-2005 FL-1002 x14’ WH-1006
Mounting Package Contents *Cable Ties* RS-1002 PL-1005 BHF-1002 10-300 PL-1004 QD-1002 46044 Ring Terminal 1/2” Plug ST-1005Px16” 46260 BHN-1001 LW-1001 OR-223 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 wire from 46044 and WH-1006 into butt connector. Using crimping tool connect 46044 and WH1006 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. Very Important: Before removing the fuel tank, identify “ALL” areas of clearance between the tank and bed to install the draw tube assembly. The closer the suction tube is placed to the center of the fuel tank, front to back and left to right, the more usable fuel there will be! B. If necessary, carefully bend the sheet metal down that is covering the side. C. This step can be omitted on 2011– models.
Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly. F. Disconnect electrical harness. Using disconnect tools, remove factory suction & return lines from fuel module. Pinch in tabs on 2011-. Disconnect overflow tube. You can now remove the fuel tank. G. Check fuel tank for good installation location of the suction tube assembly. Remove the lock ring on top. Mark location of Fuel Module in relation to the tank. Remove Fuel Module.
J. Place the suction tube assembly into the hole. Take measurements so the bottom of the suction tube is only 1/8” (no more than 2 quarters stacked) from the bottom of the fuel tank. Before cutting the suction tube, triple check the measurements. It is more efficient to cut the tube too long and then correct to proper length than it would be to cut too short. K. With proper length being obtained with the suction tube, de-bur and flush assembly. Slide tube through hole, lock washer, and nut.
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.
A. Route suction line from Step 2L 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. B. Install in-line fuel filter in an accessible location in the suction line using the HC-1001’s. Making sure the fuel flow travels the direction of the arrow on the canister. Note: Inline filter will need to be replaced every 6,000 miles. C. Using oil, insert PL-1005 into FL-1002 fuel line. Connect to the ‘E’ port of the FASS pump.
F. Carefully re-bend sheet metal back to original shape to protect fuel tank, if needed. G. Re-install driveshaft Note: Secure all fuel lines with cable ties. Cable ties are an economical way to prevent the possibility of problems occurring! 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.
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.
