INSTALLATION MANUAL FASS FUEL SYSTEM MODEL NO.
FROM: Diesel Performance Products, Inc. SUBJECT: Welcome/Thank You TO: Valued Customer We at Diesel Performance Products, Inc. (DPP) would like to thank you for your confidence in purchasing one of the FASS Products. Building a quality product and providing excellent customer service is # 1 at DPP. Behind each fuel system/fuel pump are many years of design experience.
STEPS TO CUSTOMER SATISFACTION We want you to be happy with your FASS Fuel System. Customer satisfaction, your satisfaction, is the all-important ingredient for success in our business, as it is in any other. Normally, warranty problems can be resolved by your Dealer’s sales or service departments. That’s why you should always talk to your Dealer’s Service department first. If you’re not satisfied with the dealership’s response at this level, Diesel Performance Products, Inc.
FILTER CROSS REFERENCE SHEET Cross Reference List for the FASS 150 Series Fuel Filter Recommended Fuel Stratapore™ or Microglass Filter Media: BRAND Part # Micron Rating Material FASS FF-1010 10 Stratapore™ FASS FF-1003 3 Stratapore™ CIM-TEK 70032 10 Microglass CIM-TEK 70213 3 Microglass Fleetguard HF6601 8 Cellulose/Synthetic Fleetguard HF6610 16 Cellulose Fleetguard HF6613 12 Microglass Fleetguard HF6607 6 Microglass Fleetguard HF6604 3 Microglass Caterpillar 3T864
WARNING!! Installing the improper FASS Fuel System or installation kit can cause severe engine damage. This installation manual applies to the FASS-150/180-1010@45psi contained in the same package. The serial number on the installation/owners manual package should match the serial number on the outside of the box. If it doesn’t, call the factory. This FASS-150/180-1010@45psi (180gph): Recommendation: FASS-150/180-1010@45psi - the Dodge Cummins Truck 1994-1998, with extreme horsepower modifications.
INSTALLATION MANUAL Welcome to the FASS Fuel/Air Separation System. The installation of the FASS FUEL SYSTEM can be relatively simple when the following steps are followed. 1. Inventory the package components completely. Notify place of purchase immediately of any parts missing or damaged. 2. We have invested many hours into the development of the installation and owner’s manual’s to simplify the installation and operation of the FASS Fuel System.
Contents Include: Description Quantity Part # 1. Pump/Filtration Unit -- -- -- -- 1 -- FASS-150 2. Fuel Pump Bracket -- -- -- -- 1 -- BR-2001 3. Owners Manual -- -- -- -- 1 -- OM-1001 4. Electrical Harness -- -- -- -- 1 -- WH-1002 5. 3/8” Fuel Line -- -- -- -- 17’ -- FL-1001 6. ¼ “mounting bolts -- -- -- (2 – 1” & 3 – 1 ½”) -- -- 7. 3/8“mounting bolt and flanged nut -- -- 6 ea. -- -- -- 8. Return Manifold -- -- -- 1 -- RM-1003 9.
Contents Include: Continued Description Quantity 21. Bulkhead O-ring 22. Part # -- -- 1 -- RS2770 3/8”mpt Suction Tube (11 ½” length) -- -- 1 -- ST-1002 23. Washer Washer (Thickness 3/16”) (Thickness 11/16”) --- --- 2 3 --- WA-1001A & WA-1001B 24.
Installation Manual FASS FUEL SYSTEM SYSTEM DIAGRAM 1. 2. 3. 4. 5. 6. 7. 8. FUEL TANK FUEL SUPPLY LINE TO PUMP UNIT PUMP/FILTRATION UNIT FUEL TO ENGINE MANIFOLD FUEL SUPPLY LINE TO INJECTION PUMP INJECTION PUMP RETURN LINE (NOTE: LINE WILL “T” INTO OVER FLOW TUBE NEXT TO FILLER NECK.) WIRE HARNESS FROM FASS FUEL PUMP TO POWER SOURCE INLET/OUTLET PORTS USED FOR PLUMBING ARE MARKED AS FOLLOWED: “T” “R” “E” “H” – – – – “G” – the fuel line from the fuel tank enters this port.
Installation Manual FASS FUEL SYSTEM Location of the FASS FUEL SYSTEM PUMP/FILTRATION UNIT The proper location of the FASS Fuel System on the vehicle is most important. • • • Best performance Protection from the elements and road debris Ease of service Suggested location: (Hint: The best place we have found on the Dodge ¾ and 1 ton trucks is on the driver’s side frame rail up underneath the bed of the truck and in front of the rear tire.
Installation Manual FASS FUEL SYSTEM BEGIN INSTALLATION STEP 1: Removing & Preparing Fuel Tank: Use the following photo’s to complete this step. Some of the photo’s are of a different application, procedures are the same. Photo 1A Photo 1B Photo 1C Photo 1D Photo 1E Photo 1F Very Important: 1. Before removing the fuel tank identify “ALL” areas of clearance between the tank and bed to install the draw tube assembly.
Installation Manual FASS FUEL SYSTEM STEP 1: Removing & Preparing Fuel Tank: Continued 2. Disconnect overflow tube from the fuel tank. 3. Disconnect the factory suction and return line. The factory lines are removed by pressing in on the two tabs located in the connecting harness. These tabs are opposite of each other. 4. Disconnect the factory electrical harness located between the suction and return lines on top of the fuel tank. 5.
Installation Manual FASS FUEL SYSTEM STEP 1: Removing & Preparing Fuel Tank: Continued 15. Cap factory suction line. 16. Reinstall fuel tank. Remember to connect both factory fuel lines, wire harness and torque tank hanger bolts to proper specifications. 17. Review photo 1F and the location of the return manifold before completing this step. Cut the rubber tube to allow the return manifold to junction with the filler tube.
Installation Manual FASS FUEL SYSTEM STEP 2: Photo 2A Preparing Suction Line and Return Line: Use the following photo’s to complete this step. Photo 2B 1. Insert the 3/8” x 1/2" (push lock x female flare) fitting into the fuel line. Remember to oil the fitting and fuel line. 2. As seen in photo 2A attach the fitting discussed in the previous step. Torque to proper specifications. 3.
Installation Manual FASS FUEL SYSTEM STEP 3: Mounting FASS System: Use the following photo’s to complete this step: Photo 3A Photo 3B Photo 3C Photo 3D 1. Assemble the fuel pump bracket to the FASS System using the 5 washers & bolts. The 2 - 3/16 washers & ¼” x 1” bolts will be used to space the bracket away from the main base of the FASS. The 3 – 11/16” washers & ¼” x 1 ½” bolts will be used to space the bracket away fro the pump assembly of the FASS. Refer to photo 2A.
Installation Manual FASS FUEL SYSTEM STEP 3: Mounting FASS System: Continued NOTE: The “L” shaped bracket attaches to the cab support on the short beds and to the bed support on the long beds. 4. Using photo’s 3C and 3D as a guide hold the FASS System (as high as possible) with both brackets attached into the mounting location. 5. While holding to the mounting location mark the mounting points. 6. Using a center punch, mark the center of each bolt location. 7.
Installation Manual FASS FUEL SYSTEM STEP 4: Installing Fuel Line: Photo 4A Use the following photo to complete this step: Photo 4B Photo 4C 1. Route fuel line from the suction port of the fuel tank to the port of the FASS System labeled with the letter “T”. Cut and attach to the push lock fitting. Remember to oil the fitting and fuel line before connecting. 2. Route the fuel line from the return manifold to the port on the FASS System labeled with the letter “R”.
Installation Manual FASS FUEL SYSTEM STEP 5: Installing Electrical Harness: Use the following photo to complete this step. 1. Connect the male end of the wire harness to the female electrical connector on the FASS System. 2. Route the wire harness along the frame rail and into the engine compartment and connect the wire extension (part #WE-1001) to the female end of the WH1002.cab. 3. Rout the red wire of the wire extension through rubber grommet located in the fire wall. 4.
Installation Manual FASS FUEL SYSTEM STEP 6: FINAL CHECK: 1. Bolts and fasteners properly tightened? 2. Electrical Harness and Fuel Lines secured or properly tightened? 3. Prime the fuel system! (Refer to owner’s manual)! 4. Check for leaks. 5. Start the engine! 6. Recheck all fluid connections and filters for leaks. NOTE: The electric fuel pump runs continuously while the engine is running. The fuel pump on the FASS System will feel warm or hot to the touch.
