INSTALLATION MANUAL
FASS FUEL SYSTEM
MODEL NO. FASS-150/180-1010@45psi
“HIGH PERFORMANCE FUEL DELIVERY SYSTEM”
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. (DPP) recommends that
you follow these steps, in order:
STEP 1:
STEP 2:
Discuss the problem with the owner or General Manager of the dealership.
If your dealership in unable to resolve the problem, contact Diesel Performance
Products, Inc. Customer Care Center in writing; the address is located on page 14 of this
manual or fax it to 636-433-5913. Be prepared to provide the Customer Center with the
following information:
• Your Name, address and daytime phone number
• Model and Serial Number (Not Model Number)
• Dealer, contact name and phone number
• Date of purchase
• Nature of Problem
Once you have followed the two steps described, a DPP representative will review your situation.
DPP will then follow up by contacting the dealer for more information. Depending on the situation a
representative from the selling dealer or a representative of DPP may elect to contact you.
Thank you for your business, from the men and women of Diesel Performance Products, Inc.
3
FILTER CROSS REFERENCE SHEET
Cross Reference List for the FASS 150 Series Fuel Filter
Recommended Fuel Stratapore™ or Microglass
Filter Media:
BRAND
FASS
Part #
Micron Rating
Material
Stratapore™
Stratapore™
Microglass
FF-1010
10
3
FASS
FF-1003
70032
CIM-TEK
CIM-TEK
Fleetguard
Fleetguard
Fleetguard
Fleetguard
Fleetguard
Caterpillar
10
3
70213
Microglass
HF6601
HF6610
HF6613
HF6607
HF6604
3T8642
8
Cellulose/Synthetic
Cellulose
16
12
6
Microglass
Microglass
3
Microglass
Cross Reference List for the FASS 150 Series Water Separator
Recommended Water Stainless Steel/Water Separator
Filter Media:
BRAND
FASS
Part #
Micron Rating
Material
WS-1001
FS1023
144
144
Stainless Steel/Water Separator
Stainless Steel/Water Separator
Fleetguard
NOTE:
The use of a hydraulic fuel filter is because the canister is much thicker and
provides more durability than a fuel filter canister.
4
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.
SAFETY GUIDELINES AND WARNINGS!
TIP!
Flush and clean all brass fittings and fuel line free from debris.
WARNING!
SECURE VEHICLE FROM ROLLING!
WARNING!
WARNING!
Use care not to drill into any electrical wires, air lines or other damageable
components when drilling.
Consult vehicle manufacturer’s instructions concerning the electrical system
before attempting any electrical connections.
CAUTION:
CAUTION:
Wear safety glasses when operating power tools such as drills and grinders or
when using a punch or chisel.
Properly secure lines to prevent chaffing.
VERY IMPORTANT: THE RETURN FUEL FITTING LOCATED IN THE BASE OF THE FASS
FUEL SYSTEM SHOULD NOT BE REMOVED. THERE IS A SPECIAL CUT IN THIS FITTING
THAT ASSISTS IN REGULATING PRESSURE. ALSO, DO NOT REMOVE ANY STEEL ALLEN
HEAD FITTINGS. THESE PORTS WERE USED IN THE MACHINING PROCESS.
5
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. Please
read the owner’s manual and the installation manual completely before attempting
installation. Understand how the system operates and installation recommendations
before beginning installation. Most of the questions that you will have will be
answered in one of these manuals. If you have a question please review the
installation or owner’s manual.
3. The installation recommendations contained herein are suggested installation
guidelines only. Each installation can and may vary considerably because of the
many options and accessories available to the truck market.
Installation personnel should use good judgment and common sense when
installing the FASS Fuel System.
If any installation procedure is uncertain, contact place of purchase.
Due to training, communication and our relationship we have with our authorized
dealers we recommend an authorized FASS Fuel Systems dealer for the installation of
the FASS System. They are prepared to install the FASS System with the most
efficiency. If a situation/problem arises during the installation they are most prepared
for that situation/problem. It may take more time for an unauthorized shop to address
the situation/problem. We will not be responsible.
Please make sure to fill out your product registration form and return the original form to
Diesel Performance Products, Inc. within 30 days of purchase accompanied with a copy of the
purchase receipt. Doing so will qualify you for the Limited Lifetime Warranty!
6
Contents Include:
Description
Pump/Filtration Unit
Fuel Pump Bracket
Owners Manual
Electrical Harness
3/8” Fuel Line
Quantity
Part #
1.
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1
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FASS-150
BR-2001
OM-1001
WH-1002
FL-1001
2.
1
3.
1
4.
1
5.
17’
6.
¼ “mounting bolts
(2 – 1” & 3 – 1 ½”)
6 ea. --
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7.
3/8“mounting bolt and flanged nut
Return Manifold -- --
3/8” x ½” (Push Lock x M PT) --
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1
2
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1
1
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2
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1
1
2
1
1
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RM-1003
PL-1001
PL-1002
PL-1003
DIPF-1002
HC-1001
HC-1004
FB-1001
MBFT
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
3/8” x ½” (Push Lock x Female Flare) --
3/8” x 3/8” (Push Lock x 90º Female Flare)
Injection Pump Fuel Line Fitting (O-ring)
3/8” Line Hose Clamp --
1 ¾” Line Hose Clamp --
Frame Bracket (“L” Shaped)
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Fuse Tap
Flag Terminal Female --
Ring Terminal --
½” x ½” (mpt x flared 90°)
Bulkhead (3/8 x 3/8) --
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187F1AG
NRB516-K
28-159
BHF-1001
7
Contents Include: Continued
Quantity
Description
Part #
21.
22.
23.
Bulkhead O-ring
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1
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RS2770
ST-1002
3/8”mpt Suction Tube (11 ½” length)
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1
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Washer
Washer
(Thickness 3/16”)
(Thickness 11/16”)
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2
3
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WA-1001A &
WA-1001B
24.
Wire Extension
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1
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WE-1001
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Installation Manual
FASS FUEL SYSTEM
SYSTEM DIAGRAM
1. FUEL TANK
2. FUEL SUPPLY LINE TO PUMP UNIT
3. PUMP/FILTRATION UNIT
4. FUEL TO ENGINE MANIFOLD
5. FUEL SUPPLY LINE TO INJECTION PUMP
6. INJECTION PUMP
7. RETURN LINE (NOTE: LINE WILL “T” INTO OVER FLOW TUBE NEXT TO FILLER NECK.)
8. WIRE HARNESS FROM FASS FUEL PUMP TO POWER SOURCE
INLET/OUTLET PORTS USED FOR PLUMBING ARE MARKED AS FOLLOWED:
“T”
“R”
“E”
“H”
–
–
–
–
the fuel line from the fuel tank enters this port.
this is the return port back to the fuel tank.
this is the port leading to the engine’s lift pump.
these are the heater ports for coolant, unidirectional. The heater DOES NOT HAVE TO
BE USED and the read plugs can be left in place.
“G”
–
this is the gauge port. A 0 – 75psi gauge is recommended if any gauge is being used.
The 2 – ½” allen head plugs have no function.
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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.)
NOTE: Throughout this manual there are photos of the FASS 150 with the previous mounting bracket (part # BR-
1001). The instructions for mounting the new bracket are the same throughout this manual except for the mounting of
this bracket to the FASS, for which there are pictures.
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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:
Before removing the fuel tank identify “ALL” areas of clearance between
the tank and bed to install the draw tube assembly.
1.
Remove the filler neck tube from the truck by loosening the clamps at both
ends.
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Installation Manual
FASS FUEL SYSTEM
STEP 1:
Removing & Preparing Fuel Tank: Continued
2.
3.
Disconnect overflow tube from the fuel tank.
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.
5.
Disconnect the factory electrical harness located between the suction and
return lines on top of the fuel tank.
Before completing the next step review photos 1B, 1C & 1E, 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!
6.
7.
8.
9.
With the fuel tank empty of fuel now remove it from the vehicle.
As seen in photo 1A remove the lock ring on the top of the fuel tank.
Once the lock ring is removed, remove pick up module from fuel tank.
Reviewing photo’s 1B and 1C, place the lock ring back into place for
measurement reasons. Lay the grommet into proper location and use a punch
to mark the center. Drill a 1 ¼” hole, catch all debris, example cup.
10.
11.
Using photo 1D assembly the pick up assembly. Use pipe tape on the pipe
threads.
Insert the grommet into the 1 ¼” hole. Place the pick up assembly into
grommet, 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.
12.
Before cutting the suction tube triple check the measurements, it is much more
efficient to cut the tube to long and then correct to proper length than it would
be to cut to short.
13.
14.
With proper length being obtained with the suction tube kit, debur and flush
assembly. Place the assembly into the grommet as seen in photo 1E.
Reinstall install pick up module.
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Installation Manual
FASS FUEL SYSTEM
STEP 1:
Removing & Preparing Fuel Tank: Continued
15.
16.
Cap factory suction line.
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. When assembling the return manifold into the filler tube position it to
where the 3/8” junction pipe aims to the outside of the bed. It may be necessary
to remove approximately ½” – ¾” of the rubber where the 3/8” junction tube
exits the manifold.
18.
Assemble the return manifold using the 2 – 1 3/4” hose clamps. Do not tighten
at this time.
13
Installation Manual
FASS FUEL SYSTEM
STEP 2:
Preparing Suction Line and Return Line:
Use the following photo’s to
complete this step.
Photo 2A
Photo 2B
1.
2.
3.
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.
As seen in photo 2A attach the fitting discussed in the previous step.
Torque to proper specifications.
Connect the opposite end of the 17’ fuel line addressed in step 2 of this
section to the 3/8” junction pipe of the return manifold using a 3/8” hose
clamp. As seen in photo 2B
2.
Now torque all hose clamps to proper specifications.
NOTE:
YES THE FUEL LINE MAKES A LOOP FROM THE TANK TO THE FILLER
TUBE. THIS WILL BE ADDRESSED LATER.
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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.
2.
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. Torque to proper
specifications.
Assemble 3/8” x 1/2" (push lock x mpt) fittings into ports label with the letters “T” and
“E” using tread tape. Refer to photo 2A. Torque to proper specifications.
Note: The FB-1001 (frame bracket) now has multiple slots, use the slots at the end of the
bracket.
3.
Assemble the FASS System with bracket to the frame bracket as seen in photo 3B
using the 4 – 3/8” bolts and flanged nuts. (NOTE: This photo is from a different make
of truck but the bracket assembly is the same.)
15
Installation Manual
FASS FUEL SYSTEM
STEP 3:
NOTE:
Mounting FASS System: Continued
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.
6.
7.
8.
While holding to the mounting location mark the mounting points.
Using a center punch, mark the center of each bolt location.
Drill 2 – 13/32 holes as seen in photo 3C to mount the frame bracket.
Using the 2 – 3/8” bolts and flanged nuts mount the frame bracket to the proper
support. Torque to proper specifications.
9.
Torque the 3/8” bolts attaching the frame bracket to the fuel pump bracket to proper
specifications.
10.
Located on the filters, apply motor oil to the o-rings. Attach fuel filter and water
separator. Torque to proper specifications.
16
Installation Manual
FASS FUEL SYSTEM
STEP 4:
Installing Fuel Line:
Use the following photo to complete this step:
Photo 4A
Photo 4B
Photo 4C
1.
2.
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.
Route the fuel line from the return manifold to the port on the FASS System
labeled with the letter “R”. Cut fuel line and insert the 3/8” x 1/2" (push lock x
female flare) fitting. Remember to oil the fitting and fuel line.
3.
4.
5.
6.
7.
Connect the female flare to the male flared fitting marked with the letter “R”.
Torque to proper specifications.
Disconnect factory fuel line from inlet side of the P7100 Injection Pump and
install the DIPF-1002, as seen in photo 4A & 4B.
Install the PL-1003 3/8” x 3/8” (push lock x 90° female flare) fitting into the fuel
line. Remember to use oil.
Attach 3/8” x 3/8” (push lock x 90° female flare) fitting to the injection pump
fitting. Torque to 18ft lbs. As seen in photo 4C.
Connect the remaining fuel line to the push lock fitting located in the port
labeled “E” on the FASS System. Remember to use oil.
8.
The return line from the injectors must be “T” into the return line of the P7100
injection pump.
17
Installation Manual
FASS FUEL SYSTEM
STEP 5:
Installing Electrical Harness: Use the following photo to complete
this step.
1.
2.
Connect the male end of the wire harness to the female electrical connector on
the FASS System.
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 WH-
1002.cab.
3.
4.
Rout the red wire of the wire extension through rubber grommet located in the
fire wall.
Using the fuse tap & flag terminal connect the “Red” lead from the wire
extension to a terminal on the circuit breaker board that is “hot” when the key is
on. Note: Connect the fuse tap to the hot side of the fuse.
5.
Using the ring terminals connect the green wire, of the WH-1002 wire harness,
to the negative post and the red wire to the positive post of the battery.
6.
7.
Secure the relay in an upright position.
Properly secure the wire harness and fuel lines with wire ties.
18
Installation Manual
FASS FUEL SYSTEM
STEP 6:
FINAL CHECK:
1.
2.
3.
4.
5.
6.
Bolts and fasteners properly tightened?
Electrical Harness and Fuel Lines secured or properly tightened?
Prime the fuel system! (Refer to owner’s manual)!
Check for leaks.
Start the engine!
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.
Please make sure to fill out your product registration form and return the original form to
Diesel Performance Products, Inc. within 30 days of purchase accompanied with a copy of the
purchase receipt. Doing so will qualify you for the Limited Lifetime Warranty!
Revised 4-22-08
19
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