Fass FA F15 220G Page 1 Installation Manual Download | Manualshive

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INSTALLATION MANUAL

APPLICATION:

FA F15 220G (220GPH @ 55psi)

Ford Powerstroke 7.3L/6.0L

*bypassing the factory Lift Pump*

Standard Pickup Truck

1999-2007

Revision Date: 10/12/2015

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Summary of Contents for FA F15 220G

Page 1: ...INSTALLATION MANUAL APPLICATION FA F15 220G 220GPH 55psi Ford Powerstroke 7 3L 6 0L bypassing the factory Lift Pump Standard Pickup Truck 1999 2007 Revision Date 10 12 2015 ...

Page 2: ... support to our network of dealers so our customers needs and expectations will be exceeded 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 ww...

Page 3: ...ons Be sure that the serial on this installation manual matches that of the outside of the box Flush and clean all brass fittings and fuel line from debris Keep debris from entering the internals of the system during installation Getting debris in the T port can lock up the motor If the motor does lock up from debris call FASS for technical assistance Be sure to utilize the inline fuel filter incl...

Page 4: ...acy and efficiency due to training communication and our relationship with our dealer network we recommend a ViP FASS dealer for the in stallation They are prepared to install the FASS fuel pumps with the most efficien cy If a situation problem arises during the installation they are the most prepared for that situation problem DPPI is not responsible for any installation mistakes 5 If you have an...

Page 5: ...ilter life and to prevent engine damage Installation Step 1 Install Electrical Harness Step 2 Prepare Suction Lines Step 3 Mount Fuel System Step 4 Install Fuel Line Step 5 Check Set Pressure Step 6 Check Installation E To Engine T Fuel Inlet Port Boost Compensation Port Adjustment Lock Nut Set screw Fuel Pressure Port ...

Page 6: ...Contents FL 1002 x14 WH 1005 BHB 1001 THB 1001 FF 3248 MP 9049 FPB 2005 PFB 2001C ...

Page 7: ...Hex Bolt 1 2 20 x 1 1 2 1 1 2 Washers 1 4 washer 1 4 Nut WE 1001 Butt Splice Ring Terminal BHF 1002 PL 1004 ST 1005Px16 BHN 1001 OR 223 HC 1001 LW 1001 RS 1002 Mounting Package Contents 1 2 Plug 10 300 PLB 1238 PL 1005 PLB 12516 Cable Ties ...

Page 8: ...ion 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 Secure Relay in an upright position as shown to prevent moisture from entering Di electric grease may be applied to prevent corrosion C Attach WE 1001 to the WH 1005 Wiring Harness Route WE 1001 red lead and the WH 1005...

Page 9: ... 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 Helpful Hints If more space is required to access the top of the fuel tank loosen the strap nuts to the end of the stud This ...

Page 10: ...er length it is easy to shave the suction tube with the razor It is more efficient to cut the tube too long and then correct to proper length than it would be to cut too short L With proper length being obtained place the assembly into the drilled hole securing the assembly using the lock washer nut Tighten Nut Loctite may be applied to the threads of the BHF 1002 for added insurance I Drill a 1 3...

Page 11: ...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 ...

Page 12: ...PUMP CAN CAUSE PREMATURE WEAR AND VOID MANU FACTURES WARRANTY 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 t...

Page 13: ...e frame rail to factory lift pump Remove the power lead from the factory lift pump F Route FASS wire harness wire extension along the frame rail to factory lift pump Remove the power plug from the factory lift pump G Cut off the power lead from the factory plug Using appropriate tools crimp the Butt Splice to the factory power lead and the WE 1001 Shrink blue cover with an appropriate heat source ...

Page 14: ...he E port of the FASS to the engines fuel feed line quick disconnect and cut to length Insert the PLB 12516 into FASS fuel line using oil Slide the PLB 12516 into the factory quick disconnect until you hear a click Lock down factory retainer clip D Bypass factory fuel pump Refer to your vehicles application Do Not use sealant on AN male flare fittings Only use sealant on threads installed into pum...

Page 15: ...LB 1238 into FASS fuel line using oil Slide the PLB 1238 into the factory quick disconnect until you hear a click Lockdown factory retainer clip 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 pre...

Page 16: ...any open ports Bolts and fasteners properly tightened Electrical harness and fuel lines secured and properly tightened Reconnect the battery Has the system been primed 1 Turn key to the ignition position turning on the FASS pump for 15 sec 2 Crank engine and allow to run for at least 1 minute Check for leaks Start the engine Recheck all fluid and filter connections for leaks This pump comes with a...

Page 17: ...nc will repair without cost any product found to be defective during the warranty period parts only or at its option will replace such products in exchange for the product Repair or replacements are warranted for the remainder of the original warranty period All Warranty claims are subject to approval by Diesel Performance Products Inc A Return Material Authorization RMA number must be obtained be...

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