FASS Duramax Flow Enhancer Install 01-12 Duramax Part 2

The FASS Duramax Flow Enhancer series designed for the 2001-2012 Chevrolet Duramax 2500 and 3500 is available at Orange County Diesel in Huntington Beach, California. If you have any questions about any other FASS product, or if you need expert assistance installing your FASS Platinum, feel free to call and speak to a FASS service professional at 714-848-2170.

This is Part 2 of a model-specific four-part series about how to install a FASS Duramax Flow Enhancer.

The 2001-2010 installation steps are very similar to the 2011-2012 Duramax's installation. The steps specific for the 11-12 installation are in green, and the steps unique to the 01-10 installation are in blue.

Please find the links to Part 1, Part 3, and Part 4 here.

Step 2: Prepare suction and feed lines.

Remove the 3 bolts holding the fuel cooler to the mounting bracket. The fuel cooler is located in front of the fuel tank.

Using a fuel line disconnect tool, disconnect the factory suction line located above the fuel cooler. Place the disconnect tool around the fuel tube and slide the tool under the fuel line connection to release the fuel line.

Pull the red square tab out and push in the rounded tab, releasing the fitting from the steel-beaded feed line.

Using oil, insert PLB-1212 into one end of the provided FL-1002 fuel line. Feed line over frame to the stock fuel connection.

Push the PLB-1212 into the factory suction line until you hear a click and the tabs are locked in place. Slide square tab back in to secure.

Using an HC-1001 hose clamp, insert the QD-1002 into the other end of the provided FL-1002 fuel line and secure.

Oil the rings inside the QD-1002 and slide over the factory feed line until you hear a click. Do not cut the line at this time.

Oil the rings inside the QD-1002 and slide over the factory feed line until you hear a click. Do not cut the line at this time.

FASS Duramax Flow Enhancer Install 01-12 Duramax Part 3

The FASS Duramax Flow Enhancer series designed for the 2001-2012 Chevrolet Duramax 2500 and 3500 is available at Orange County Diesel in Huntington Beach, California. If you have any questions about any other FASS product, or if you need expert assistance installing your FASS Platinum, feel free to call and speak to a FASS service professional at 714-848-2170.

This is Part 3 of a model-specific four-part series about how to install a FASS Duramax Flow Enhancer.

The 2001-2010 installation steps are very similar to the 2011-2012 Duramax. The steps specific for the 11-12 installation are in green, and the steps unique to the 01-10 installation are in blue.

Please find the links to Part 1, Part 2, and Part 4 here.


Step 3: Mount FASS Fuel Pump

Position FB-4002 bracket to mounting location on the cross member directly in front of the fuel tank making sure there are no obstructions.

Position system to mounting location on the cross member directly in front of the fuel tank making sure there are no obstructions. The pump should be mounted parallel to the frame.

Make sure the mounting holes are not located on the radium bend of the cross member. Using template, mark holes. Pre-drill with 1/8" bit and final drill with 5/16" bit.

The weep hole must face down for proper pump operation. Any other direction will void your warranty.

Mount pump to the cross member using 5/16" bolts.

Reach between the cross member and the bed to install the 3 bolts and tighten with a 1/2" socket.

The DIPF fitting does not require sealant on it’s threads. It is an O-ring sealed fitting. Install two DIPF-1003 fittings into the Inlet/Outlet ports on the DMAX. Torque to 18 ft./lbs.

Connect the male end of the wire harness to the female electrical connector on the FASS pump. Turn key to the “On” position. With the FASS pump on, squirt a liberal amount of WD-40 or other lubricant into the Inlet port. This procedure will “wet” the Gerotor and allow for better suction during initial priming.

FASS Duramax Flow Enhancer Install 01-12 Duramax Part 1

The FASS Duramax Flow Enhancer series designed for the 2001-2012 Chevrolet Duramax 2500 and 3500 is available at Orange County Diesel in Huntington Beach, California. If you have any questions about any other FASS product, or if you need expert assistance installing your FASS Platinum, feel free to call and speak to a FASS service professional at 714-848-2170.

This is Part 1 of a model-specific four-part series about how to install a FASS Duramax Flow Enhancer.

The 2001-2010 installation steps are very similar to the 2011-2012 Duramax. The steps specific for the 11-12 installation are in green, and the steps unique to the 01-10 installation are in blue.

Please find the links to Part 2, Part 3, and Part 4 here.

Step 1: Install electrical harness.

Crimp the ring terminals to the red and green wires of the WH-1006 Wire Harness. Attach red wire to the positive terminal of the battery and the green terminal to the negative terminal.

Secure relay and fuse in an upright position, as shown, to prevent moisture from entering. Di-electric grease may be applied to prevent corrosion.

Guide the single red wire from the relay to the engine bay fuse panel.

Guide the single red wire extension through the fire wall grommet to the fuse panel.

Using the fuse tap and flag terminal, connect the red lead to a terminal on the circuit board that is “hot” when the key is on. Route WH-1006 wire harness along frame rail to mounting location of pump.

FASS Duramax Flow Enhancer Install 01-12 Duramax Part 4

The FASS Duramax Flow Enhancer series designed for the 2001-2012 Chevrolet Duramax 2500 and 3500 is available at Orange County Diesel in Huntington Beach, California. If you have any questions about any other FASS product, or if you need expert assistance installing your FASS Platinum, feel free to call and speak to a FASS service professional at 714-848-2170.

This is Part 4 of a model-specific four-part series about how to install a FASS Duramax Flow Enhancer.

The 2001-2010 installation steps are very similar to the 2011-2012 Duramax. The steps specific for the 11-12 installation are in green, and the steps unique to the 01-10 installation are in blue.

Please find the links to Part 1, Part 2, and Part 3 here.

Step 4: Install fuel lines

Route suction line from Step 2d to the Inlet port. Cut FL-1002 to needed length.

Using oil, insert PL-2003 and connect to the DIPF-1003. Torque to 18 ft./lbs.

Install in-line fuel filter in an accessible location in the suction line using the HC-1001s. Make sure the fuel flow travels the direction of the arrow on the canister.

Measure from the factory feed connection from Step 2e to the Outlet port of the FASS pump. Cut and insert PL-2003.

Connect to the Outlet DIPF-1003. Torque to 18 ft./lbs. Secure all fuel lines and electrical harness with wire ties.

FASS HD Install Class 8

The FASS HD series designed for Class 8/Semis is available at Orange County Diesel in Huntington Beach, California. If you have any questions about any other FASS product, or if you need expert assistance installing your FASS HD, feel free to call and speak to a FASS service professional at 714-848-2170.

The FASS HD shares the same installation steps as the FASS Platinum for Class 8 applications. Please find the links to Part 3, Part 4, and Part 5 here.

Step 1: Installing electrical harness.
The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes. Use of corrosion preventative spray and dielectric grease is recommended where electrical connection is made.

Select best location in firewall for passage of wiring harness from cab to engine compartment. Find or drill a 7/8” hole in firewall. Install RS-2684 grommet for ease of installation and protection of wire harness. Route red wire/ loom of the WH-1001 wire harness through the grommet in the fire-wall to the ignition or fuse panel.

Using a spade terminal, connect the "Red" lead to the "ON" terminal of the ignition switch on the circuit breaker board that is "hot" when the key is on.

Using a spade terminal, connect the green wire of the wire harness to the negative post of the battery or clean ground. Secure fuse out of the weather, then secure all electrical leads and harness.


The steps presented here in Part 2 are ONLY to be used as a guideline, as your application may be different.

Use thread tape or pipe sealant on ALL male pipe threads, do not use on male flared AN fittings.

Remove primary fuel and/or water separator. If primary filter is part of the fuel pump, ignore this step.

ONLY if a 90° fitting is to be used, follow these steps: Remove 4 bolts holding upside-down T Block pump assembly to the FASS filter base. Pay attention to the O-rings and ball. Remove fuel manifold and assemble 90° fitting directing it in the correct direction. Reassemble fuel manifold then pump assembly to FASS filter base, seating all O-rings & the ball in their proper place. Torque to 110 in./lbs.

Attach BR-2001 to back of system using the spacers and 1/4" bolts. Use the 2 shortest on the system base.

Position system where it will be mounted. Mark the 4 mounting points using the template located in the table of contents. Prior holes may be used. Drill these marked locations with a 13/32 bit.

Prior to installing pump, connect wire harness and turn on pump. Spray liberal amount of WD-40 or similar lube into water separator nipple. This wets the Gerotor and allows for easier initial priming. Assemble to frame using the (4) 3/8" bolts & flange nuts placing the RS-1001 between the frame and bracket.

Apply motor oil to O-rings located on filters. Attach to system and torque appropriately.

FASS Titanium Install Class 8 Part 5

The FASS Titanium series designed for Class 8/Semis is available at Orange County Diesel in Huntington Beach, California. If you have any questions about any other FASS product, or if you need expert assistance installing your FASS Platinum, feel free to call and speak to a FASS service professional at 714-848-2170.

This is Part 5 of a model-specific five-part series about how to install a FASS Platinum fuel system.

Please find the links to Part 1, Part 2, and Part 3, and Part 4 here.

Step 5: Fuel Supply Line

The fuel supply line connects directly to engine. The primary fuel filter is not remote mounted. (Usually, not always, on NTC/STCs and N-14s)

It is very important to blow this fuel line out before final assembly to engine.

Attach the fuel supply line from the fuel tank to the FASS using a 10-272L or one of the fitting from the filter housing previously removed in Part 2.

Attach the fuel supply line from the FASS to the engine pump using a 10- 272L or one of the fittings from the filter housing previously removed.

FASS Titanium Install Class 8 Part 4

The FASS Titanium series designed for Class 8/Semis is available at Orange County Diesel in Huntington Beach, California. If you have any questions about any other FASS product, or if you need expert assistance installing your FASS Platinum, feel free to call and speak to a FASS service professional at 714-848-2170.

This is Part 4 of a model-specific five-part series about how to install a FASS Platinum fuel system.

Please find the links to Part 1, Part 2, and Part 3, and Part 5 here.

The double-draw/double return and the single-draw/single return fuel line systems share instructions. The steps pertaining to the the single-draw/single return system are indicated in green. Please follow all instructions in descending order.

Do not use sealant on AN fittings. Only use sealant on threads installed into pump assembly or joining fittings.

The single-draw/single return system resembles the following picture:

The double-draw/double return system resembles the following three pictures:

Return line from FASS with straight ends to cross member where the line will "T" off.

Assembled "T"

From "T" to each fuel tank with 1-straight fitting & 1-90° fitting on each line. These lines must be the exact length on both sides.

Locate a fuel return port into the fuel tank. Most KWs have a 1/4”. Peterbilts have 3/8" or 1/2" extra pipe plug located by the fuel lines at the top of the fuel tank. Other models may have an extra port somewhere at the top of the fuel tank. Remove the plugs and install the –8 ANx5/16 NPT into each tank. It may be necessary to use a brass bushing.

Install –8 AN hydraulic fitting into fuel line.

Assemble fuel line into female hose fitting (reverse threads). Apply a modest amount of oil to the interior lining.

Secure female end in vise.

Oil male end of 90° JIC swivel fitting and assemble into female end.

Completely tighten the male portion.

Assemble the "T" using (1) 3/8 NPT "T", (2) -8 ANx3/8 MPT & (1) -8 ANx3/8 MPT 90°.

Attach the line to the return port of the FASS labeled "R." Route to the center of the nearest cross member aligned with the ports in the fuel tank being used for return fuel. Measure & mark this line as it will connect to the 90° fitting of the "T" in this location.

Cut the fuel line and assemble a –8 AN hydraulic fitting in the opposite end of the line connecting to the "R" port of the FASS.

Assemble a –8 AN hydraulic fitting into one end of the remaining fuel line. Route this fuel line from straight fitting of the "T" to the return port in the fuel tank, mark & cut.

Route the side with the exhaust first. It will be necessary to travel below the frame to avoid the exhaust.

Each side must be exactly the same length. Assemble (1) of each –8 AN 90° & -8 AN Straight into each line.

Route and loosely connect the assembled fuel lines to the appropriate points of connection, including the "T."

Torque all connections to 18 ft./lbs. Secure the fuel line and all fittings.