INSTALLATION MANUAL APPLICATION: FA F15 200G (200G @ 55psi) Ford Powerstroke 7.3L/6.
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 F15 200G Recommended Application Powerstroke (6.0/ 7.3L) 1999—2007 with 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 200 GPH 60 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 Lines Mount Fuel System Install Fuel Line Check/Set Pressure Check Installation
Contents THB-1001 FF-3248 BHB-1001 MP-9049 FPB-2005 PFB-2001C WH-1005 FL-1002 x14’
Mounting Package Contents RS-1002 PLB-12516 PL-1004 *WE-1001* BHF-1002 10-300 1/2” Plug BHN-1001 *Cable Ties* PLB-1238 PL-1005 Butt Splice Ring Terminal HC- OR-223 LW-1001 1 ST-1005Px16” 1/2” Washers 1 Hex Bolt 1/2” -20 x 1 1/2” 1/4” Nut 1/4” washer 4 1/4 - 20x1.75” RS-2001 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. Disconnect battery before beginning installation. Using ring terminals, attach red wire of the WH-1005 to the positive battery terminal. The use of corrosion preventative spray is recommended. Attach green wire to a clean ground, preferably the negative battery terminal. Secure fuse block in a location protected from outside elements. B.
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. Remove the filler neck and overflow tubes from the truck by loosening the clamps at both ends.
H. Before drilling marked location, clean area of debris. Using the photo double check area selected for any interference including the fuel level arm. I. Drill a 1 3/8” hole, catching all debris. De-bur hole and remove any missed debris in the fuel tank. J. VERY IMPORTANT: Support fuel tank on both ends allowing the natural formation of the tank to take place. Failure to perform this step can and will create an issue with less usable fuel! K.
Some of the photo’s are of a different application, procedures are the same. A. Insert PFB-2001C in to bed channel align the nut with the opening on the channel. . B. Secure PFB-2002 and RS-2001 with (1) hex bolt 1/2” -20 x 1 1/2” and (1) 1/2” washer to FPB-2005 C. Secure THB-1001 to bolt on bracket with the RS-1002 and the (5)-1/4-20x1 bolts, 1/4 washers, and 1/4 nuts. With the (4)-1/4-20x 1.75” bolts thread the BHB-10001 to the THB-1001. Note: Use of Anti-seize compound is highly recommended.
D. Using thread tape, install the 2 10-300 into the “T” & “E” ports. Torque to 40 ft./lbs. Connect the male end of the wire harness to the female electrical connector on the FASS pump. Reconnect the battery. Turn key to the “On” position. With the FASS pump on, squirt a liberal amount of WD-40 or other lubricant into the “T” port. This procedure will “wet” the Gerotor and allow for better suction during initial priming. Note: Do Not Put Thread Tape on Flare of Fitting E.
F. G. F. Route wire harness/wire extension along the frame rail to factory lift pump. Remove the power lead from the factory lift pump. Cut off the power lead terminal. Using appropriate tools, crimp the Butt Splice to the factory power lead and the WE-1001. Shrink blue cover with an appropriate heat source. Route FASS wire harness/wire extension along the frame rail to factory lift pump. Remove the power plug from the factory lift pump. Factory power plug G.
Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly. A. Route fuel line from the suction tube assy. to the suction port on the FASS pump labeled “T”. Cut the fuel line. Insert PL-1005 into fuel line using oil. Attach to 10-300 in ‘T’ port. Torque to 18 ft./lbs. B. Install in-line fuel filter in an accessible location in the suction line using the HC-1001’s. Make sure the fuel flows in the direction of the arrow on the canister.
E. Drain fuel from factory pump/filter using a 6mm hex drive, turning it counterclockwise. F. Using quick disconnect tools, remove the fuel lines from the front of the factory fuel pump. Remove the fuel lines attached to the rear of the factory fuel pump by pressing in on the blue tabs. G. Route the fuel line from the “E” port of the FASS to the engines fuel feed line quick disconnect and cut to length. Insert the PLB-1238 into FASS fuel line using oil.
The preset pressure is approximately 60 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.
