Related Manuals for Fass HEAVY DUTY Series
Summary of Contents for Fass HEAVY DUTY Series
- Page 1 INSTALLATION MANUAL APPLICATION: HD D08 095G (95gph @ 16psi) HD D08 150G (150gph @ 16psi) Cummins 5.9L 24 Valve 1998.5-2004...
- Page 2 Building extremely “High-Quality” fuel products is our business. We concentrate all of our efforts in this arena. No one else is as specialized as FASS in what we do! This is one of the ingre- dients to insure you are running with the “Highest-Quality” fuel system in the world! We have im- plemented very rigorous testing procedures to provide the “Highest Quality”...
- Page 3 ¡WARNINGs! Read all instructions before starting installation of this product! Installing the improper FASS Pump can cause severe engine damage. FASS Recommended Application Cummins 1998.5-2004 with stock - moderate horse power modifications HD D08 095G Cummins 1998.5-2004 with moderate - extreme horsepower modifications...
- Page 4 4. For best results in accuracy and efficiency (due to training, communication, and our relationship with our dealer network), we recommend an Authorized or ViP FASS Fuel Systems dealer for the installation. They are prepared to install the FASS fuel pumps with the most efficiency. If a situation/problem arises during the installation, they are the most prepared for that situation/problem.
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Page 5: Installation
Heavy Duty Series 95 or 150 GPH 16 PSI (Approximately) A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage! “H” Coolant Heater “E” To Engine ‘T’ Fuel Inlet ‘R’ Fuel Return Electric Heater... - Page 6 Contents MP-9008 WH-1002 FB-1001 FL-1001 x17’ BR-2001...
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Page 7: Mounting Template
Mounting Package Contents RS-1001 RM-1002 DIPF-1001 PL-1002 10-301 10-300 PL-1003 QD-1001 Ring Terminal HC-1001 7 Hex Bolt 3/8” -16x 1 1/4” Locking Nut 3/8” HC-1004 Mounting template 3 WA-1001B 3 Hex Bolt 1/4”-20x11/2” 2 WA-1001A 2 Hex Bolt 1/4”-20x1”... - Page 8 Secure the electrical wire with wire ties. Please remember wire ties are inex- pensive and can prevent major problems! f. Route the WH-1002 wire harness along the frame rail to the mounting loca- tion of the FASS fuel pump.
- Page 9 Prepare Suction and Return Line Some of the photo’s are of a different application, procedures are the same. a. Prepare FASS return line by cutting rubber junction connecting the filler neck to the fuel tank. b. Filler neck removed for clarity. Insert & position, into cut filler neck, RM- 1002 with the junction pipe aiming to outside of bed.
- Page 10 Attach BR-2001 to back of system using 2 - 1” & 3 - 1.5” Hex bolts with 2 - WA-1001A & 3 - WA-1001B spacers. Torque to 110 in./lbs. c. Assemble the FASS pump brackets with the RS-1001 spacer between. Hold pump up to the mounting location for rough fitting. Once location is established, use template located on the contents page to accurately mark drill points.
- Page 11 Step 3: Mount Fuel System Continued f. Connect factory plug into the FASS harness. Plug FASS harness into the fuel module in tank. Make sure to lock red slide tab. Plug female plug of the FASS harness into pump. Turn key to “on”. With pump operating (you may have to bump the starter), turn pump over, liberally spray WD-40 (or equivalent) into water separator nipple lubricating Gerotor.
- Page 12 This retro- fit will not allow fuel to be drawn through the FASS pump! Order a STK (Suction Tube Kit) from FASS.
- Page 13 Step 4: Install Fuel Line, Continued Refer to these steps for routing the fuel line to the inlet port of the VP44 (Injection Pump) for 1998.5 – 2002 trucks. d. Disconnect factory fuel line from inlet side of the factory injection pump, Install the DIPF-1001 fuel fitting into this inlet port.
- Page 14 Answer the following questions: Did the vehicle start fine without the FASS or HPFP? Do you have high mileage on the VP44? If yes, have your VP44 checked. Has the VP44 been subjected to a PSI of 5 or less? Has the VP44...
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