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29,561 Posts
Submitted By: mrpeal
Date: October 31, 2008, 04:18:19 AM
Views: 5427

F.A.S.S. Filtration Systems Installation How To - mrpeal

Next is to find your spot to mount the fuel pump assembly, as per the instructions the best place is driverside beside the stock tank and right under the bed.

(figure 5)​

i decided to get the brackets mounted to the pump and get it done first thing. so as per the instructions and they do have photos as well attach the brackets to the pump assembly.

(figure 6)​

once this is attached your ready to drill your holes in the body mount bracket on the truck. as you can see set it up and drill one hole using the bracket as a template, then bolt it up and drill the other keeping the bracket level. there is lots of adjustment in the bracket so getting close is fine.

(figure 7)​

next i bolted up the pump assembly to the supplied bracket that i now had attached to the body mount bracket, i installed the 4 3/8 bolts and set the pump to where i had just a bit of clearance between the bed and top of pump assembly.

(figure 8 and 9)​

i took off the filters to make it easier as can be seen in photos, now i installed the filters on the pump assembly, note i installed the fuel inlet and outlet fittings before hand as it was easier to do on the bench, they are all labeled with engravings to make it very easy to install the hoses to the correct location.

(figure 10)​

see engravings in figure 11 and 12

(figure 11 and 12)​

next i moved on to tapping my return port into the stock filler neck, it recommends removing the stock filler hose to do this but i managed to shave some time by just cutting it with a razorblade and removing 1 inch section of the hose, make sure the return pipe is pointing towards the bed as to flow the extra fuel back down into the tank and not into the filler neck. use supplied hose clamps and tighten.

(figure 13 and 14)​

Figure 15 shows closeup of the pipe adapter

(figure 15)​

now we are going to attach the pump to the tank, using the supplied hose use the push on fittings to push the hose onto the fitting labeled T which goes to tank. i added a hose clamp just because i like extra protection but these barbed fittings do not require it, lightly lubricate them with engine oil and push them onto the barbs.

(figure 16)​

Next from under the truck look ontop of the fuel tank and you will see the feed inlet for the tank, compress the two plastic ends to release the stock fuel line and remove from tank, you can remove the line completely from the truck or just seal it off and tuck neatly underneath. figure 18 shows it in the way you will find it when you get there.

(figure 17)(figure 18 )​

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Now the feed line from the FASS to the injection pump, we use the port above the port labeled R and we install the hose to it,

(figure 19)​

Run it neatly along the frame of the truck and secure it via clamps or tie straps to make it secure all the way under the hood.

(figure 20)(figure 21)​

now using the supplied fittings remove the stock inlet fuel line and banjo fitting, plug the stock line going to the tank and install the supplied fitting and 90 fitting onto it. It will be the one on the right. after installed cut the hose to length and attach the hose to the barbed end. use hose clamp for extra protection from leakage.

(figure 22)(figure 23)​

Figure 24 shows the fitting attached looking down from the air intake side.

(figure 24)​

Now we go back to the pump and install the return line from the R port back to the pipe adapter we installed in the fuel filler hose. just attach to the pump again by lubing with engine oil and then attaching to pipe with hose clamp.

(figure 25)(figure 26)​

next is the harness, it is very simple attach the harness end with plug directly to new pump assembly, then run wiring up to the cab and plug female end to the stock connector of original plug, this will be the control circuit for the pump relay, then run the red and black wires to battery positive and negative, i used the positive terminal in the stock fuse block to keep it clean.

(figure 27-30)​

now if your planning on installing a fuel pressure guage or already have one there is a great little port already for you on the back of the pump. i recommend installing this last as i had to use a 90 fitting to make room for it. then fun wiring for the guage and we are ready to prime the tank.

(figure 31)​

now we are ready to prime, turn the key on but do not start, then bump the starter for just a second, just enough to engage the starter but not to crank, this will energize the pump for 30 seconds or so, do this a few times if you have a guage and watch for a guage reading, or without a guage i would do it a few times and loosen the fuel inlet on the injection pump and watch for fuel, once you have fuel pressure to the injection pump do it one more time and then lets start the truck. if it is hard to start apply the throttle a bit while cranking and it should fire right up for you. mine didnt miss a lick. and here is the guage readings i got right after install.This guage had a bad ground i figured out which allowed higher number, the actual number now is 15psi solid.

(figure 32)​

here is a few shots of the assembly in the truck and clearance shots.

(figure 33 and 34)​

i have to say this pump does what it says, it has not dropped a bit and my actual guage readings are right at 15psi no matter what i do. normally with my programmer set on 4 and getting on it my guage would drop to about 8psi and now it wont budge a bit no matter what i do, even pulling my fifth wheel loaded or the gooseneck with 10k on it.

Hope this helps someone install this unit as i think it is the greatest add on for the 24 valve trucks for reliability as well as performance.
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