INSTALLATION MANUAL APPLICATION: FA F17 200G (200gph @ 55psi) Ford Powerstroke 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 F17 200G Recommended Application Powerstroke (6.7L) 2011 - 2012 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 55 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 Line Mount Fuel Pump Install Fuel Line Check/Set Pressure Check Installation
Contents THB-1001 FF-3248 BHB-1001 MP-9071 FPB-2005 FL-1002 x9’ WH-1005
Mounting Package Contents 46044 RS-1002 BHF-1002 *WE-1001* RVC-12 RVC-38 10-300 DB-4646 PLB-1212 BHN-1001 Cable Ties PL-1004 PL-1005 1/2” Plug Ring Terminal OR-223 HC-1001 LW-1001 1 Hex Bolt 1/2” -20 x 1 1/2” ST-1005Px16” 46260 1 1/2” Washers 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 46044 and the WE-1001. B. Place wire from 46044 and WE-1001 into butt connector. Using crimping tool connect 46044 and WE1001 with butt connector. Install 46260 to 46044 bottom slot (opening that is near the spade). Route 46044 lead through the fire wall using existing grommet. C.
The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes. E. Connect the WE-1001 Extension to the WH-1005’s shorter relay branch. Route the extension to the engine bay fuse panel. Remove a fuse (maximum of 10A) that is “hot” when the key is on. Example: #54 or #55. Use a test probe to locate the “hot side” of the circuit in the fuse block. Install the fuse tap into the open location.
Some of the photo’s are of a different application, procedures are the same. Helpful Hint: Directions for removing factory lines. 1. Pull up on the locking tab (either blue or yellow), 2. Push in slightly on the connector, 3. Press down on the release tab, 4. Pull the connector straight off, A. Very Important: Before removing the fuel tank identify “ALL” areas of clearance between the tank and bed to install the draw tube assembly.
F. Note the location of the tab and arrow. Re-install the sending unit in the same location to prevent the fuel level arm from binding. G. Once the lock ring is removed, carefully remove pick up module from fuel tank without bending fuel level arm. H. Place the tank on blocks to simulate the tank hanging. Failure to do this step may result in the draw tube being cut too short. NOTE: Hose clamps are not recommended for push lock fittings.
K. Once location has been established, double check! Make sure the fuel line and fittings will clear the trimmed protective shell. Mark location and drill 1 1/2” hole with hole saw. Hold a cup or catch can inside the tank while drilling to catch any debris. Place a rag over the opening to prevent tank contamination. Double check for debris around the ring and inside tank. L. De-burr hole and check for fit. M.
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.
Do Not use sealant on AN (Male Flare) fittings. Only use sealant on threads installed into pump assembly. A. Route suction line from the suction tube assembly to the ’T’ port on the FASS pump. Cut the fuel line and insert PL-1005 using oil. Attach to 10-300 in ‘T’ port. Torque to 18 lb./ft.² B. Install in-line fuel filter in an accessible location in the suction line using the HC-1001’s. Make sure the arrow is in the direction of the fuel flow. .
F. Using oil, insert PLB-1212 into one end of FL-1002 fuel line. Oil the PLB and slide into the yellowclipped factory feed fitting until you hear a click. Push down the locking tab. G. Disconnect both factory return lines from the factory lift pump (Refer to diagram at the beginning of Step 2). Insert DB-4646 into each return line fitting until you hear a click and tabs lock. H. Clean and cap off the factory return ports with the two RVC-38 caps.
The preset pressure is approximately 55 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.
