Fass T D08 095G Installation Manual Download Page 14 | Manualshive

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Step 3:

Mount Fuel System

I.

Apply motor oil to gasket located on filters. Attach to system and
hand tighten.

Fuel Filter –Install FF-3003 on
side of pump with draw tube in
the middle of the filter nipple.

Water Separator Filter –Install FS-
1001 on water separator nipple without
the draw tube. Make sure to insert O-
Ring provided on nipple.

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Summary of Contents for T D08 095G

Page 1: ...LLATION MANUAL APPLICATION T D08 095G 95GPH 16 18psi T D08 150G 150GPH 16 18psi Cummins 5 9L 24 Valve Standard Pickup Truck 1998 5 2004 Note Cab and Chassis may require modifications Revision Date 10 12 2015 ...

Page 2: ...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 www FASSrid...

Page 3: ...ne damage Secure vehicle from ROLLING Cab and Chassis may require modifications Consult vehicle s manufacturers instructions concerning the electrical system before at tempting any electrical connections 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 t...

Page 4: ...ts in accuracy and efficiency due to training communication and our relationship with our dealer network we recommend a ViP FASS dealer for the installation They are prepared to install the FASS fuel pumps with the most effi ciency If a situation problem arises during the installation they are the most pre pared for that situation problem DPPI is not responsible for any installation mis takes 5 If...

Page 5: ...4 Install Fuel Line Step 5 Check Installation 95 or 150 GPH 16 18 PSI Approximately A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage R Fuel Return to Tank E To Engine Serial Number Location G Fuel Pressure T Fuel Inlet Electric Heater Port H Coolant Heater 2nd Electric Heater Port ...

Page 6: ...Contents FL 1002 x17 WH 1002 MP 9020 PBR 2001 PFB 2002 ...

Page 7: ...Package Contents PL 1005 10 301 10 300 PL 2003 DIPF 1003 QD 1001 RM 1004 HC 1004 HC 1001 Ring Terminal 4 Hex Bolt 3 8 16x 1 1 2 3 Hex Bolt 1 4 20x1 3 4 4 Locking Nut 3 8 3 WA 1001D 4 3 8 Washers RS 2002 RS 2001 ...

Page 8: ...attach red wire of the WH 1002 to the positive battery terminal Attach green wire to a clean ground preferably the negative battery terminal Secure fuse block in a location protected from outside elements The use of corrosion preventative spray is recom mended E Route the WH 1002 wire harness along the frame rail to the mounting location of the FASS fuel pump Step 1 Install Electrical Harness The ...

Page 9: ...e QD 1001 addressed in the previous step Loop fuel line over frame will be addressed in step Installing Fuel Line Plug or seal factory line or remove B Filler neck removed for clarity Insert position into cut filler neck RM 1004 with the junction pipe aiming to outside of bed Clamp rub ber and RM 1004 using both HC 1004 s and factory clamps Step 2 Prepare suction Return lines Some of the photo s a...

Page 10: ...NOTE ATTENTION While installing fittings into Titanium pump DO NOT Apply side pressure to draw tube of pump Improper Proper ...

Page 11: ...ommended B For fitting purposes Secure PBR 2001 to pump assembly lightly with 3 1 4 20x1 3 4 bolts and 3 WA 1001D This will assembly will be used in future steps for correct fitting of brackets Note Bracket maybe flipped to accommodate your application NOTE Before installing fittings make sure to inspect for burs or flare imperfections When cutting fuel line make sure to blow out line to keep debr...

Page 12: ...erally spray WD 40 or equivalent into water separator nipple lubricating Gerotor E Position the PBR 2001 to the PFB 2002 pump assembly at the mounting location and check for fit Once location is established mark location for mounting in next step D Secure PFB 2002 and RS 2001 with bed bolt in previous step C Unbolt driver side front bed bolt from bed retain bolt for future use Align RS 2001 with P...

Page 13: ...e 3 1 3 4 bolts and 3 WA 1001D spacers to mount the pump to the bracket G Assemble the FASS pump bracket PBR 2001 using the RS 2002 spacer between PFB 2002 and PBR 2001 bracket with 4 3 8 bolts nuts and washers Note Torque bolts not flange nut ...

Page 14: ...ilters Attach to system and hand tighten Fuel Filter Install FF 3003 on side of pump with draw tube in the middle of the filter nipple Water Separator Filter Install FS 1001 on water separator nipple without the draw tube Make sure to insert O Ring provided on nipple ...

Page 15: ...02 to length Insert PL 1005 in line using oil Attach to 10 301 Torque to 18 ft lbs B Route fuel line from the R fitting to RM 1004 in the filler neck with a gentle bend Cut and insert the PL 1005 fitting to the hose Use oil Attach fitting to the R port Torque to 18 ft lbs C Insert PL 1005 in remaining fuel line Connect to the E port of the FASS system Use oil Torque to 18 ft lbs Route this line up...

Page 16: ...on pump E Measure and cut fuel line Insert PL 2003 90 Push Lok fitting using oil Install fitting to DIPF 1003 Torque to 18 ft lbs Note Secure all fuel lines with cable ties Cable ties are an economical way to prevent the possibility of problems occurring The factory suction line can be capped off or removed from the truck Make sure to drain fac tory filter The openings on the filter and tank will ...

Page 17: ...rrent flash for your truck Do you have a WH 1002 If yes refer to the WH 1002 section located in Electrical Step 5 Review Installation Blow out any open lines cover 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 ...

Page 18: ...e O Ring must be put back on suction side of pump Failure to do so can result in priming issues cavitation or pressure loses To assist with priming your FASS pump crack the FF 3003 Put power to the FASS pump to activate the pump When the tone of the pump changes you can tighten up the fuel filter If you need a video of the priming process go to www FASSride com Step 5 Review Installation ...

Page 19: ...5 4M Donaldson P551000 10M Donaldson P551311 3M Donaldson P551001 10M Donaldson P551313 3M Fleetguard FS1282 14M Donaldson P553203 3M Fleetguard FS 1000 10M Donaldson P557440 6M Fleetguard FS 1001 10M Fleetguard FF5320 2M Fleetguard FS 1009 14M Fram P8334 2M Fleetguard FS 1212 14M Hastings FF1079 2M LuberFiner LFF8011 Wix 33352 6M LuberFiner LFF8000 Wix 33528 2M Motorcraft FD818 14M Wix 33674 2M W...

Page 20: ...el Performance Products Inc 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 peri od All Warranty claims are subject to approval by Diesel Performance Products Inc A Return Material Authorization RMA ...

Page 21: ...NOTES ...

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