FASS Titanium Install 01-05 Chevy Duramax 2500, 3500 Part 2

The FASS Titanium series designed for the 2001-2005 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 Platinum fuel system.

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

Step 2: Prepare suction and return lines.
Hose clamps are not recommended for push lock fittings. They will hold up to 300 psi.

Using the fuse tap & flag terminal, connect the red lead to a terminal on the circuit board that is “hot” when the key is on.

Using a fuel line disconnect tool, disconnect the factory suction 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.

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 a click is heard and the tabs are locked in place.

Using an HC-1001 hose clamp, insert the QD-1002 into the other end of the provided FL-1002 fuel line and secure. Loop this end over the frame to the factory steel fuel line previously disconnected. Oil the rings inside the QD-1002 and slide over the line until you hear a click. Do not cut the line at this time.

Some models have an integrated over-flow tube inside the filler neck. If your filler neck does not have a separate over-flow tube, you have an integrated filler neck.

Mark location for the Return manifold on the rubber over-flow tube. Loosen the clamps on both ends of the filler neck and remove screws from fuel receptacle. Remove filler neck assembly. Slide rubber outer hose down exposing filler tube. At mark, cut hose. Slide top half over filler tube with HC-1003 clamp. Slide RM-1001 Return Manifold over the filler tube and into overflow hose with the small junction pipe pointing towards the fender. Slide another HC-1003 clamp and bottom hose over filler tube and secure. Re-install filler neck assembly.

OR

Prepare FASS return line by cutting rubber junction connecting the two halves of the filler neck. Position RM-1001 with the 1/2" junction pipe aiming to outside of bed. Clamp rubber and RM-1001 using both HC-1003's.  

Position RM-1001 with the junction pipe aiming to outside of bed. Connect rubber and RM-1001 using both HC-1003's.