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aFe Power DFS 780 Instruction Manual

Advanced flow engineering
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advanced FLOW engineering
Instruction Manual
Make: GM Model: Diesel Trucks Year: 2001-2010 Engine: V8-6.6L (td) Duramax
Fuel Pressure: 8-10 psi (relay controlled)
P/N: 42-14011
DFS 780

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Summary of Contents for aFe Power DFS 780

  • Page 1 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 • Please read the entire instruction manual before proceeding. • Ensure all components listed are present. • If you are missing any of the components, call customer support at 951-493-7100. • Ensure you have all necessary tools before proceeding. • Do not attempt to work on your vehicle when the engine is hot. •...
  • Page 3 aFepower.com Page 3...
  • Page 4 REMOVAL Figure 1 Step 1: Looking at the driver’s side of the truck, on the inside of the frame rail, you will see two hard lines. These are the fuel supply and return lines for the engine. They are held in place by plastic retainers that are bolted to the frame (shown above).
  • Page 5 INSTALL Figure 2 Step 4: Gently pull the fuel lines/retainers off of the frame rail. Be careful not to bend or kink the fuel lines. Step 5: Place the supplied carbon steel frame bracket between the frame and the stock fuel line retainer located in Step 2.
  • Page 6 INSTALL Rear of truck Figure 3 NOTE: This is what the bracket looks like when installed correctly. Page 6...
  • Page 7 INSTALL Figure 4 Step 7: Mount the supplied fuel manifold assembly to the carbon 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.
  • Page 8 INSTALL Figure 5 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. Page 8...
  • Page 9 INSTALL Figure 6 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. aFepower.com Page 9...
  • Page 10 INSTALL “AN fitting” side “NPT” side Figure 7 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. Page 10...
  • Page 11 INSTALL Figure 8 Step 11: Install the 2 x 3/8" NPT to -8 AN fittings into the fuel manifold assembly (as shown above). Page 11 aFepower.com...
  • Page 12 INSTALL Figure 9 NOTE: 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. Page 12...
  • Page 13 INSTALL Figure 10 NOTE: This is what the connections look like on the 2009 – 2010 truck. Page 13 aFepower.com...
  • Page 14 INSTALL Figure 11 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. Page 14...
  • Page 15 INSTALL Figure 12 Step 13: Disconnect the 1/2" fuel feed line. NOTE: 2009 -2010 model shown in the pictures. Page 15 aFepower.com...
  • Page 16 INSTALL INSTALL Figure 13 Step 14: Install the straight 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. Page 16...
  • Page 17 INSTALL 90 ° Female quick disconnect Figure 14 Step 15: Install the 90° female 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.
  • Page 18 INSTALL Center of truck Figure 15 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. Page 18...
  • Page 19 INSTALL Figure 16 Step 17: Disconnect the stock fuel return line. NOTE: 2009 - 2010 model shown in the pictures. Page 19 aFepower.com...
  • Page 20 INSTALL Figure 17 Step 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 Page 20...
  • Page 21 INSTALL Figure 18 Figure 18 Step 19: Install the straight 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. Page 21 aFepower.com...
  • Page 22 INSTALL Figure 19 Figure 19 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. Page 22...
  • Page 23 INSTALL Figure 20 Figure 20 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. Page 23 aFepower.com...
  • Page 24 INSTALL Figure 26 Figure 21 Step 22: Install the fuel return hose (-4 AN fitting) onto male -4 AN fitting on the top of the sight glass cover. Page 24...
  • Page 25 INSTALL Figure 22 Step 23: Using the supplied nylon cable ties, secure the new hoses (as shown above). NOTE: 2009 - 2010 model shown in the pictures. aFepower.com Page 25...
  • Page 26 INSTALL Figure 23 Step 24: Using the supplied nylon cable ties, secure the new hoses (as shown above). Page 26...
  • Page 27 INSTALL Figure 24 Step 25: From the inside of the frame, plug the Deutsch connector on 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.
  • Page 28 REMOVE Remove the 4 Bolts Figure 25 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. Page 28...
  • Page 29 INSTALL Figure 26 Step 29: Run the other end of the power harness along the inside of the frame into the engine compartment. Page 29 aFepower.com...
  • Page 30 INSTALL Figure 27 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. Page 30...
  • Page 31 INSTALL Figure 28 Step 31: Connect the black wire ring terminal on the power harness to the negative side of the battery. Page 31 aFepower.com...
  • Page 32 INSTALL Figure 29 Step 32: Plug the supplied relay harness into the Deutsch connector on the power harness. Page 32...
  • Page 33 INSTALL Figure 30 Step 33: Secure the relay harness using a supplied cable tie. Page 33 aFepower.com...
  • Page 34 INSTALL Figure 31 Step 34: Attach the power wire from the relay harness to the add a harness fuse adapter. Page 34...
  • Page 35 INSTALL Figure 32 Step 35: Remove the fuse box cover. Step 36: Find a 12 volt source inside the fuse box that 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: 2002:...
  • Page 36 INSTALL Figure 33 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). Page 36...
  • Page 37 INSTALL Figure 34 Step 38: Install the add a harness fuse adapter (with installed fuses) into the 12 volt source location chosen in Step 36. Page 37 aFepower.com...
  • Page 38 INSTALL Figure 35 Step 39: Carefully route the power wire outside the 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. Page 38...
  • Page 39 INSTALL Figure 36 Step 42: Turn the key to the “Run” position and watch to see if the sight glass fills with fuel. If the sight glass does not fill with fuel, use the tank valve (on the top of the sight glass cover) to release any trapped air.
  • Page 40 PAGE LEFT BLANK INTENTIONALLY Page 40...
  • Page 41 PAGE LEFT BLANK INTENTIONALLY Page 41 aFepower.com...
  • Page 42 Rear Differential Cover Turbocharger Transmission Pan Intake System “Momentum” P/N: 46-70012-WL P/N: 46-60100 (LB7) P/N: 46-70242 (Black) P/N: 50-74001 (LB7) 46-70240 (RAW) 50-74002 (LLY) 50-74003 (LLY/LBZ) 50-74004 (LMM) Torque Converter Intake Manifold Fuel Filter Oil Filter P/N: 43-14011 P/N: 46-60039-1 P/N: 44-FF011 P/N: 44-LF001 (LBZ/LLY/LMM)
  • Page 43 DFS FUEL SYSTEM “WORRY FREE” WARRANTY POLICY Please read this warranty policy before proceeding with the installation of this advanced FLOW engineering, Inc. (aFe) product. aFe’s obligation under the “Worry Free” Warranty is covered for two years from date of purchase. The “Worry Free” Warranty is limited to replacement of the defective or worn-out product with the same (or comparable) product in ac- cordance with this warranty.
  • Page 44 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...