aFe Power dfs780 Instruction Manual Download

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advanced FLOW engineering

DFS 780

Instruction Manual

P/N: 42-14011

Make:

Model:

Diesel Trucks

Year:

2001-2010

Engine:

V8-6.6L (td) Duramax

Fuel Pressure:

8-10 psi (relay controlled)

Summary of Contents for dfs780

Page 1: ...advanced FLOW engineering DFS 780 Instruction Manual P N 42 14011 Make GM Model Diesel Trucks Year 2001 2010 Engine V8 6 6L td Duramax Fuel Pressure 8 10 psi relay controlled ...

Page 2: ...to AN 8 Black 05 60685 M 1 Harness Relay 05 60551 N 1 Connector Add a harness Fuse 05 60583 O 1 Hose Fuel Return 05 60689 P 12 Ties Nylon Cable 12 05 60167 Q 1 Harness Power 05 60632 R 1 Hose Fuel Inlet 05 60673 S 1 Hose Fuel Outlet 05 60681 Please read the entire instruction manual before proceeding Ensure all components listed are present If you are missing any of the components call customer su...

Page 3: ...aFepower com Page 3 O A B L K D C F G I N S E M P R Q H J ...

Page 4: ...urn lines for the engine They are held in place by plastic retainers that are bolted to the frame shown above Step 2 Locate the retainer that is below the driver s side door labeled as 2 above Step 3 Remove the nuts from the backside of the three 3 stock fuel line retainers leave the fuel lines in their retainers REMOVAL Page 4 1 Figure 1 2 3 ...

Page 5: ...stock fuel line retainer located in Step 2 Step 6 While making sure the carbon steel frame bracket is sitting on the bottom of the frame reinstall and tighten the factory nuts removed in Step 3 NOTE If the fuel line retainers are not there please use the supplied hardware to attach the bracket to the frame 1 M8 x 1 25 x 25mm bolt 1 M8 washer 1 M8 locknut INSTALL aFepower com Page 5 Figure 2 ...

Page 6: ...NOTE This is what the bracket looks like when installed correctly Page 6 Rear of truck INSTALL Figure 3 ...

Page 7: ... steel frame bracket using the supplied hardware and tighten 4 M6x1 0 x 50mm bolts 4 M6 washers 4 M6 fiber washers 4 M6 flanged locknuts NOTE The fiber washers go between the fuel manifold assembly and the carbon steel bracket INSTALL aFepower com Page 7 Figure 4 ...

Page 8: ...Step 8 Turn sight glass to the desired angle and using a 1 1 4 wrench tighten the center nut under the fuel manifold NOTE The pump should look like the picture above Figure 5 INSTALL Page 8 ...

Page 9: ...wer com Page 9 7 Step 9 Using a light oil lube the gasket on the supplied fuel filter and install on the fuel manifold assembly Thread the supplied water separator bowl onto the fuel filter Figure 6 INSTALL ...

Page 10: ...Step 10 Apply Teflon tape with PTFE or Teflon paste with PTFE to the 2 x 3 8 NPT to 8 AN fittings NOTE Only apply Teflon to the NPT side of the fitting Figure 7 INSTALL Page 10 AN fitting side NPT side ...

Page 11: ...Step 11 Install the 2 x 3 8 NPT to 8 AN fittings into the fuel manifold assembly as shown above Page 11 7 Figure 8 INSTALL aFepower com ...

Page 12: ...E If you have a 2001 2008 truck and the fittings look like the above picture you will need a special tool to release the fuel line from the connectors You can get this tool at your local parts store Figure 9 INSTALL ...

Page 13: ...aFepower com NOTE This is what the connections look like on the 2009 2010 truck Figure 10 INSTALL Page 13 ...

Page 14: ...Page 14 7 Step 12 Clean the area around the fuel lines to prevent dirt and debris from going into the lines NOTE 2009 2010 model shown in the pictures Figure 11 INSTALL ...

Page 15: ...aFepower com Step 13 Disconnect the 1 2 fuel feed line NOTE 2009 2010 model shown in the pictures Figure 12 INSTALL Page 15 ...

Page 16: ...ht male quick disconnect fitting on the supplied fuel inlet hose silver 90 8 AN fitting shown below into the female side of the stock fuel feed line NOTE 2009 2010 model shown in the pictures INSTALL Page 16 7 Figure 13 INSTALL ...

Page 17: ...male quick disconnect fitting on the supplied fuel outlet hose black 90 8 AN fitting shown below onto the male side of the stock fuel feed line NOTE 2009 2010 model shown in the pictures Figure 14 INSTALL Page 17 90 Female quick disconnect ...

Page 18: ...Page 18 Step 16 Locate the factory fuel return line It is located at the front of the fuel tank near the center of the truck NOTE 2009 2010 model shown in the pictures Figure 15 INSTALL Center of truck ...

Page 19: ...aFepower com Step 17 Disconnect the stock fuel return line NOTE 2009 2010 model shown in the pictures Figure 16 INSTALL Page 19 ...

Page 20: ...p 18 Install the straight male quick disconnect fitting on the supplied fuel return hose shown below into the female side of the stock fuel return line NOTE 2009 2010 model shown in the picture 7 Figure 17 INSTALL ...

Page 21: ...raight female quick disconnect fitting on the fuel return hose shown be low onto the male connection of the stock fuel return line NOTE Make sure that the line doesn t not kink while making connections Figure 18 Page 21 Figure 18 INSTALL ...

Page 22: ...Page 22 7 Step 20 Install the fuel inlet hose silver 90 8 AN fitting onto the male 8 AN fitting on the fuel inlet port of the fuel manifold assembly Figure 19 7 Figure 19 INSTALL ...

Page 23: ...aFepower com Step 21 Install the fuel outlet hose black 90 8 AN fitting onto the male 8 AN fitting on the fuel outlet port of the fuel manifold assembly Figure 20 Page 23 Figure 20 INSTALL ...

Page 24: ...Page 24 7 Step 22 Install the fuel return hose 4 AN fitting onto male 4 AN fitting on the top of the sight glass cover Figure 26 Figure 21 INSTALL ...

Page 25: ...aFepower com Page 25 7 Step 23 Using the supplied nylon cable ties secure the new hoses as shown above NOTE 2009 2010 model shown in the pictures Figure 22 INSTALL ...

Page 26: ...Page 26 Step 24 Using the supplied nylon cable ties secure the new hoses as shown above Figure 23 INSTALL ...

Page 27: ...n the supplied power harness into the mating connector on the fuel pump motor Step 26 Route the power harness along the inside of the frame towards the front of the vehicle Step 27 Organize the power harness and secure with the supplied nylon cable ties Figure 24 INSTALL Page 27 ...

Page 28: ...Page 28 Step 28 Remove the four 4 bolts holding the corner brace in the engine compartment Re move the brace and hardware and retain for re installation Figure 25 REMOVE Remove the 4 Bolts ...

Page 29: ...aFepower com Step 29 Run the other end of the power harness along the inside of the frame into the engine compartment Figure 26 INSTALL Page 29 ...

Page 30: ...Step 30 Connect the red wire ring terminal to the positive side of the battery NOTE Check the fuse to make sure it is already installed in the connector Figure 27 INSTALL Page 30 ...

Page 31: ...Page 31 Step 31 Connect the black wire ring terminal on the power harness to the negative side of the battery Figure 28 INSTALL aFepower com ...

Page 32: ...Step 32 Plug the supplied relay harness into the Deutsch connector on the power harness Figure 29 Page 32 INSTALL ...

Page 33: ...Page 33 Step 33 Secure the relay harness using a supplied cable tie Figure 30 INSTALL aFepower com ...

Page 34: ...Step 34 Attach the power wire from the relay harness to the add a harness fuse adapter Figure 31 Page 34 INSTALL ...

Page 35: ...t only comes on with the key in the run position Once a 12 volt source is located pull fuse from the fuse box Locations for inline fuse adapter plug in underhood fuse block 2001 15 2002 53 2003 2006 SEO IGN marked on the cover of fuse panel 2007 2008 42 2009 2010 40 Figure 32 INSTALL aFepower com ...

Page 36: ...Step 37 Install the fuse removed in Step 36 into the open location on the add a harness fuse adapter not in line with the wire Figure 33 Page 36 INSTALL ...

Page 37: ...Page 37 Step 38 Install the add a harness fuse adapter with installed fuses into the 12 volt source location chosen in Step 36 Figure 34 INSTALL aFepower com ...

Page 38: ... fuse box and reinstall the cover making sure not to pinch the wire Step 40 Organize the wire harnesses and secure with the remaining nylon cable ties Step 41 Reinstall the corner brace using the hardware removed from Step 28 Figure 35 Page 38 INSTALL ...

Page 39: ...to release any trapped air If the sight glass still does not fill try starting the engine Step 43 Installation is now complete Make sure that all fittings are tight and that fuel is not leaking from any of the connections made while installing NOTE Place enclosed CARB EO sticker on or near the device on a smooth clean surface EO identification label is required to pass the smog test inspection Fig...

Page 40: ...Page 40 PAGE LEFT BLANK INTENTIONALLY ...

Page 41: ...Page 41 aFepower com PAGE LEFT BLANK INTENTIONALLY ...

Page 42: ...rbocharger P N 46 60100 LB7 Rear Differential Cover P N 46 70012 WL Transmission Pan P N 46 70242 Black 46 70240 RAW Intake System Momentum P N 50 74001 LB7 50 74002 LLY 50 74003 LLY LBZ 50 74004 LMM Intake Manifold P N 46 60039 1 LBZ LLY LMM Torque Converter P N 43 14011 Fuel Filter P N 44 FF011 Oil Filter P N 44 LF001 ...

Page 43: ...installation of the products in question Registration Process Simply register your DFS Fuel System product online at http www aFepower com reg Claim Process To file a warranty claim customers are required to submit their information using the warranty claim form online at http afepower com inquiries tech warranty php All Warranty Claims require 1 Online registration of the product 2 If item has no...

Page 44: ...7 advanced FLOW engineering inc 252 Granite Street Corona CA 92879 TEL 951 493 7100 TECH 951 493 7100 x23 E Mail Tech aFepower com P N 06 80830 ...

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