INSTALLATION MANUAL APPLICATION: T D02 095G (95gph @ 8psi) T D02 150G (150gph @ 8psi) Cummins 5.
Dear Valued Customer, “Made in the USA” is not just a slogan at FASS; it’s what we live by! FASS is not only assembled in the USA but 98%+ of the FASS product is manufactured in the USA, helping to employ Americans and strengthen America. At FASS, we scrutinize our suppliers and demand the highest quality American-made components. However, this does come at a price, which is one of the main reasons FASS products are more expensive than the competition.
¡WARNINGs! Read all instructions before starting installation of this product! Installing the improper FASS Pump can cause severe engine damage. FASS Recommended Application T D02 095G Cummins 1989-1993 with stock - moderate horsepower modifications T D02 150G Cummins 1989-1993 with moderate - extreme horsepower modifications Note: Because of the higher fuel flow these systems have to offer, you may encounter problems with the stock fuel module.
INSTALLATION MANUAL Follow these steps to ensure a simple installation of your new FASS TITANIUM FUEL SYSTEM 1. Read the installation manual completely before attempting installation. The installation of this product indicates that the buyer has read and understands the limitations of the FASS manufacturers warranty agreement and accepts the responsibility of its terms and conditions. 2. Inventory the package components. Notify the place of purchase immediately of any parts missing or damaged. 3.
Titanium Series 95 or 150 GPH 8 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 to Tank 2nd Electric Heater Port Electric Heater Port ‘G’ Fuel Pressure Serial Number Location Installation Step 1: Step 2: Step 3: Step 4: Step 5: Install Electrical Harness Prepare Suction and Return Lines Mount Fuel System Install Fuel Line Check Installation
Contents MP-9019 WH-1002 PBR-2001 PFB-2002 FL-1002 x17’ PFB-2001C
Mounting Package Contents *WE-1001* RM-1003 PL-1005 PL-2003 10-300 HC-1004 10-301 QD-1001 HC-1001 Ring Terminal DIPF-1003 1 1/2” Washers 1 Hex Bolt 1/2” -20 x 1 1/2” 4 4 Hex Bolt 3/8” -16x 1 1/2” 3 Locking Nut 3/8” 3 Hex Bolt 1/4”-20x1 3/4” WA-1001D 3/8” Washers 46260 46044 RS-2002 4 RS-2001
The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes later in the installation. A. Using wire stripping tool remove excess insulation off the add-a-fuse and the WH-1005. B. Connect WE-1001 to the WH-1002. Place wire from 46044 and WE-1001 into butt connector. Using crimping tool connect 46044 and WE-1001 with butt connector. Install 46260 to 46044 bottom slot (opening that is near the spade).
E. If fuse panel is located in the cab it will be necessary to guide the single red wire from the relay through the fire wall grommet to access the fuse panel. F. Locate fuse box under hood and select ignition hot fuse. Remove fuse and put Add-A-Fuse in place. Install fuse previously removed. The use of a corrosion preventative on electrical connections is recommended. G. Route WH-1002 wire harness along frame rail to mounting location of pump.
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 two halves of the filler neck. Loosen the factory clamps at the tank. Push the lower half filler neck into the tank enough to insert RM-1003. As seen in the following photo. 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. B.
A. Using thread tape, install the 10-300 into “E” and the 10-301 into the “T” port (on opposite end). Torque to 40 lb./ft.² Note: Do Not Put Thread Tape on Flare of Fitting ***The use of thread sealant is not recommended*** 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 brackets. (Note: Bracket maybe flipped to accommodate your application.
C. . Insert PFB-2002C 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 E. Connect factory plug into the FASS harness. Plug FASS harness into the fuel module in tank. Make sure to lock red slide tab. Connect female plug of the FASS harness into pump. Turn key to “on”.
F. 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. G. Assemble the FASS pump bracket PBR-2002 using the RS-2002 spacer between PFB-2002 and PBR2001 bracket with 4-3/8 bolts, nuts, and washers. Note: Torque bolts not flange nut. H. Once secure use 3-1 3/4 bolts and 3-WA-1001D spacers to mount the pump to the bracket.
I. Apply motor oil to gasket located on filters. Attach to system and hand tighten. Fuel Filter –Install FWS-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. 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.
Caution: Do not use sealant on AN fittings. Only use sealant on threads going into the FASS pump. A. Route suction line to ‘T’ port . Cut FL-1002 to length. Insert PL1005 in line using oil. Attach to 10-301. Torque to 18 ft./lbs. NOTE: Hose clamps are not recommended for push lock fittings and can damage the strength of hose. They will hold up to 300psi! Use oil on fittings and inside fuel line when installing Push-Lok fittings B.
Remove inlet fuel line from the factory filter housing. Pinch in tabs and pull off factory fitting on the inlet side. Unbolt and remove the factory lift pump. Use a Big Block Chevy block off plate to seal engine block. Drain filter, blow out fuel lines and cover or plug any open ends. 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.
To assist with priming your FASS pump crack the FWS-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 heat the fuel in the Winter months.
Disclaimer: 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.FASSride.com, click “Find a Dealer”, put in their ZIP code, select the type of dealer, and see if the company you purchased from is listed.
