Fass TS-F14-125G, Installation Manuals

Page 1: ... Bypassing the Factory Lift Pump 1999 2003 Powerstroke 6 0L Bypassing the Factory Lift Pump 2003 2007 Standard Pickup Truck APPLICATION TITANIUM SIGNATURE SERIES INSTALLATION MANUAL ALL 1 2 FUEL PORTS LIFETIME WARRANTY AVAILABLE Note Cab and Chassis may require modifications Manufacture Date ...

Page 2: ...e quality expand our product line and provide superb support Our exclusive ViP Network ensures that customers receive the proper products and support at the local level The extended four year warranty is only available on products purchased from the network There is no warranty on products not purchased outside the network IMPORTANT In order to qualify for the Lifetime extended warranty your produ...

Page 3: ...nty is void Return the FASS product to the seller and get a refund 2 It is registered within thirty 30 days of purchase Other conditions may apply please see full warranty information ATTENTION Before you begin installation Register for your Warranty ONLINE at https www fassride com register a warranty No online access call our TECH Support at 1 866 769 3747 NOTE Warranty is void if product was pu...

Page 4: ...service at 636 433 5410 or send us an e mail techsupport FASSride com with the following information FOLLOW THESE STEPS TO ENSURE A SIMPLE CORRECT Serial TITANIUM FUEL SYSTEM INSTALLATION OF YOUR NEW If you have any questions or concerns that cannot be addressed with your dealer email or call FASS Be sure to identify the proper FASS System and fuel line configuration For help our product finder ca...

Page 5: ...ep debris from entering the internals of the system during installation Getting debris in the water separator nipple can lock up the motor If the motor does lock up from debris call FASS for technical assistance 9 Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel 10 Properly secure lines to prevent chaffing BEFORE STARTING THE INSTALLATION P...

Page 6: ...ew Installation PUMP GUIDE 1 Serial Number 2 E To Engine 3 R Fuel Return to Tank 2nd Heater Port 4 T Fuel Inlet 5 Electric Heater Port 6 G Fuel Port 7 H Coolant Heater 1 2 3 4 5 6 www fassride com 866 769 3747 TITANIUM SIGNATURE SERIES 125 GPH 70 75 PSI Approximately Note Going over 100 PSI WILL void warranty 7 Front View Rear View ...

Page 7: ...ATURE SERIES 125 GPH 70 75 PSI Approximately Note Going over 100 PSI WILL void warranty NOTE WARRANTY MAY BE VOID IF SILICONE BAND IS REMOVED FROM MOTOR The silicone band is in place to retain motor wires preventing damage to the electric motor ...

Page 8: ...CONTENTS NOTE Owner s Manual available for download on our website www FASSride com www fassride com 866 769 3747 FL 1058x3 MP 9045 PFB 2001C FL 1002x14 WH 1005 2 PBR 2001 PFB 2002 ...

Page 9: ...002 TWO 2 RINGTERMINAL 10 302 10 300 PL 1004 TWO 2 PLB 12516 PLB 1238 PL 1010 OR 223 BHN 1001 LW 1 2 WASHERS PL 1058 HEXBOLT1 2 20x13 4 WE 1001 CABLETIES BUTTSPLICE FOUR 4 HEXBOLT3 8 16x11 2 THREE 3 HEXBOLT 1 4 20x13 4 FOUR 4 LOCKING NUT3 8 THREE 3 WA 1001D FOUR 4 3 8 WASHERS ...

Page 10: ...de com 866 769 3747 MOUNTING PACKAGE CONTENTS ST 1005Px16 RS 2001 RS 2002 RS 2001C OR 030 TWO 2 OR 017 NOTE THESESPAREBASEO RINGS AREINCLUDED WITHTHE KITINTHEEVENTOFAPINCHEDO RING DURING ASSEMBLY DIELECTRICGREASE ...

Page 11: ...ide com 866 769 3747 The installation of the electrical harness is done first allowing power to be applied to the pump for lubrication purposes later in the installation NOTE USE SUPPLIED DIELECTRIC GREASE SPARINGLY ON ALL ELECTRICAL CONNECTIONS ...

Page 12: ... clean ground preferably the negative battery terminal Secure fuse block in a location protected from outside elements The use of a corrosion preventative on electrical connections is recommended 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 2 Wiring Harness Route WE 1001 red l...

Page 13: ... clearance you want to install it as close to the Fuel sending unit as possible B Remove the filler neck and overflow tubes from the truck by loosening the clamps at both ends Helpful Hint If more space is required to access the top of the fuel tank loosen the strap nuts to the end of the stud This will gain you about 3 more working room C Disconnect factory suction and return lines by pinching in...

Page 14: ...side fuel line when installing Push Lok fittings H Assemble the BHF 1002 with the PL 1010 in port S using thread tape the PL 1004 in port R DO NOT USE THREAD TAPE ON PL 1004 FITTING IS EQUIPPED WITH THREAD SEALANT Torque fittings to 20 ft lbs Push the ST 1005P onto the barb portion of the BHF 1002 Insert O ring into groove I Before drilling marked location clean area of debris Using the photo doub...

Page 15: ... of the fuel tank Using a razor knife make multiple cuts to insure proper 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 M 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 a...

Page 16: ...ROPER STEP 2 PREPARE SUCTION RETURN LINES O Push one end of 1 2 fuel line onto R port of suction tube assy one end of the 5 8 onto the S port Loop fuel line over frame Do not cut at this time Reinstall fuel tank making sure to reconnect factory suction line factory return line and electrical connections Torque hanger bolts to factory specifications ...

Page 17: ...ater separator not doing this could lead to priming issues A Install 10 300 into the E port and 10 302 into the T port of the FASS torque to 20 ft lbs FITTINGS COME EQUIPPED WITH THREAD SEALANT DO NOT USE THREAD TAPE 10 302 10 300 B For fitting purposes Secure PBR 2001 to pump assembly lightly with 3 1 4 20x1 3 4 bolts and 3 WA 1001D Assembly will be used in future steps for correct fitting of bra...

Page 18: ...PFB 2002 and RS 2001C RS will make contact with bed channel when assembled correctly Insert the PFB 2002 assembly in to bed channel align the nut with the opening on the channel D Secure PFB 2002 and RS 2001 with 1 hex bolt 1 2 20 x 1 1 2 and 1 1 2 washer to PFB 2002C ...

Page 19: ...wire harness before mounting into position F Cut off the power lead terminal Using appropriate tools crimp the Butt Splice to the factory power lead and the WE 1001 Shrink blue cover with an appropriate heat source 2003 2007 WITH 6 0L POWERSTROKE E Route FASS wire harness wire extension along the frame rail to factory lift pump Remove the power plug from the factory lift pump Be sure to finish con...

Page 20: ...he factory power lead and the WE 1001 Shrink blue cover with an appropriate heat source G 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 H Position the PBR 2001 to the PFB 2002 pump assembly at the mounting location and check for fit ...

Page 21: ...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 J Once secure use 3 1 3 4 bolts and 3 WA 1001D spacers to mount the pump to the bracket K Apply motor oil to gasket located on filters Attach to system and hand tighten ...

Page 22: ... Separator Filter Install FS 1001 on water separator nipple without the draw tube Make sure to insert O Ring provided on nipple Note O Ring must be put back on suction side of pump Failure to do so can result in priming issues cavitation or pressure loses NOTE If fuel pressure gauge is pulsating after FASS installation use snubber valve Cat Part 7S 3795 ...

Page 23: ...ttings They will hold up to 300psi Use oil on fittings and inside fuel line when installing Push Lok fittings B Route fuel line from the R port of the suction tube assy to the R port on the FASS system with a gentle bend Cut and insert PL 1005 using oil Attach fitting to the R port Do not use any sealant Torque to 18 ft lbs C Insert PL 1005 into remaining fuel line using oil Attach fuel line to th...

Page 24: ...the fuel line from the E port of the FASS to the factory lift pump s 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 2003 2007 WITH 6 0L POWERSTROKE D Bypass factory fuel pump E Drain fuel from factory pump filter using a 6mm hex drive turning it counte...

Page 25: ...ing oil Slide the PLB 1238 into the facto ry quick disconnect until you hear a click Lock down factory retainer clip H Measure between the two factory return fittings Insert two PLB 12516 fittings into the provided FL 1002 fuel line using oil Insert fuel line into factory quick disconnects until you hear a click Lock down retainer clip Secure fuel line F Using quick disconnect tools remove the fue...

Page 26: ...ed Reconnect the battery 4 Has the system been primed a Turn key to the ignition position turning on the FASS pump for 15 sec b Crank engine and allow to run for at least 1 minute 5 Check for leaks 6 Start the engine 7 Recheck all fluid and filter connections for leaks 8 This pump comes with a 1 Year Manufacturer s Warranty based on the date it has been manufactured To receive your extended Lifeti...

Page 27: ...canister 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 Note The Red Plastic Plugs located in the H ports can stay in place fuel will not flow through these ports Coolant can be plumbed into these ports to he...

Page 28: ...ack of filtration Warranty is voided if used with other than diesel fuel Returned items will arrive prepaid to the place of purchase Diesel 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 orig...