FASS Duramax Series Information

The FASS Duramax Series Pump is very similar in design to the FASS Dodge Direct Replacement Pump, except it was created for the General Motors Duramax V-8 engine released in their light- and medium-duty trucks. Because Duramax trucks are not built with a stock lift pump that pulls fuel to the truck’s tank, the system constantly introduces air and vapor into the fuel. By installing the FASS Duramax Series Pump, your truck uses this pusher-styled pump to supply fuel to the engine. As a result, the vacuum effect that is naturally created by your truck is mostly eliminated. Consequently, your fuel system will then have significantly reduced air and vapor.

The Duramax Series Pump was designed to flow at approximately 70 Gallons per Hour at 10 PSI. FASS recommends this pump for users that are happy with stock power applications. However, owners with very slight horsepower modifications can also use the Duramax Series Pump. Owners that desire a fuel pump for moderate to extreme power applications for their light-duty truck should explore the FASS Titanium or Platinum Series. 

FASS has made available two models of the FASS Duramax Pump compatible with two different versions of the GM Duramax. The first model is compatible with 6.6L Duramax LB7, LLY, LBZ, LMM 2500, and LMM 3500 from 2001 to 2010.The second model works with the newer 2011-2012 6.6L Duramax LML 2500 and LML 3500.

The FASS Duramax Series Pump will help your machine in conditions that are either extremely cold or hot. By using a heavy-duty motor that delivers a high torque to gear ratio, cold weather starts become seamless. In warmer climates, the Duramax Series Pump's heavy-duty motor has the strength to process B-20 and B-50 fuels. This means that the FASS Duramax Series Pump will operate effectively regardless of the temperature of your environment.

The instruction manual for the Duramax Series Pump recommends using a fuel pressure gauge in order to identify the stage of your fuel filter’s life. Using this gauge will help you prevent engine damage. The manual also mentions that increased fuel flow may create problems with your stock fuel module. Using the included FASS suction tube kit with the Duramax Series Pump can prevent these problems.

The FASS Duramax Series Pump comes standard with a four-year warranty, so long as the manufacturer receives all relevant warranty information during the first 30 days after purchase.

Please see the OC website for the FASS Duramax Series Pump. If you have any questions about the FASS Duramax Series Pump or any other FASS product, feel free to call and speak to a FASS service professional at 714-848-2170.

FASS Titanium Install 98.5-04 In Tank Lift Pump, 05-12 Dodge Cummins 5.9L, 6.7L Part 1

The FASS Titanium series designed for the 2005-2012 Dodge Cummins 5.9L/6.7 L and the 1998.5-2004 Dodge with in tank lift pump 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 Platinum fuel system.

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

Step 1: Install electrical harness.

The electrical harness is installed first in order for power to be applied to the pump for lubrication purposes.

Using ring terminals, attach red wire of the WH-1004 to the positive battery terminal. Attach green wire to a clean ground, preferably the negative battery terminal. Secure fuse block in a location protected from outside elements.

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

Route wire harness along frame to the approximate mounting location near the fuel tank.

FASS Titanium Install 98.5-04 In Tank Lift Pump, 05-12 Dodge Cummins 5.9L, 6.7L Part 3

The FASS Titanium series designed for the 2005-2012 Dodge Cummins 5.9L/6.7 L and the 1998.5-2004 Dodge with in tank lift pump 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 Platinum fuel system. 

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

Step 3: Mount fuel system.

Using thread tape, install the 10-298 into "E."

Install the 10-299 into the "T" port on the opposite end.

Attach BR-2001 to back of system using 5 1 1/4” Hex bolts and WA-2001 spacers. Torque to 110in/lbs.

Assemble the FASS pump brackets using the RS-1001 spacer between. Hold pump up to the mounting location for rough fitting. Once location is established, use the mounting template on the contents page to accurately mark drill points.

Position the pump assembly at the mounting location and check for fit.

Once location is established, use template from back of manual to mark drill points.

Pre-drill holes. Final drill with 3/8” bit.

Connect factory plug into the FASS harness. Plug FASS harness into the fuel module in tank. Lock red slide tab. Plug female plug of the FASS harness into pump. 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.

Using the 3/8” bolts, secure FASS with brackets to previously drilled mounting holes.

Apply motor oil to gasket located on filters. Attach to system and hand-tighten.

FASS Titanium Install 98.5-04 In Tank Lift Pump, 05-12 Dodge Cummins 5.9L, 6.7L Part 2

The FASS Titanium series designed for the 2005-2012 Dodge Cummins 5.9L/6.7 L and the 1998.5-2004 Dodge with in tank lift pump 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 line.

Before removing the fuel tank, identify all areas of clearance between the tank and bed to install the draw tube assembly. The closer the suction tube is placed to the center of the fuel tank, front to back and left to right, the more usable fuel there will be.

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 give you 3" more working room.

Remove the filler neck and overflow tubes from the truck by loosening the clamps at both ends.

Disconnect the factory suction and return line. The factory lines are removed by pressing in on the two tabs located in the connecting fuel line. Keep the tab on the factory return. Disconnect the factory electrical harness on top of the fuel tank. With the fuel tank empty of fuel, remove it from the vehicle.

Clean the fuel module area then remove the lock ring on the top of the fuel tank.

Remove pick-up module from fuel tank once the lock ring is removed.

Assemble the BHF-1002 with the PL-1004 in ports "S" and "R" using thread tape, along with pushing the ST-1005P onto the barb portion of the BHF-1002. Insert O-ring into groove. Torque to 40 ft./lbs.

Before drilling marked location, clean area of debris. Double-check area selected for any interference, including the fuel level arm.

Drill a 1 1/2” hole, catching all debris. De-bur hole and remove any debris in the fuel tank.

Support fuel tank on both ends to allow natural formation of the tank to take place. Failure to perform this step can and will create an issue with less usable fuel.

Place the bulkhead assembly into the drilled hole. Take measurements so the bottom of the suction tube is only 1/8" from the bottom 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.
FY.I., it is more efficient to cut the tube too long and then correct to proper length than it would be when cut too short.

With proper length obtained, place the assembly into the drilled hole, securing the assembly using the lock washer and nut. Torque nut. Loctite may be applied to the threads of the BHF-1002 for added insurance.

Carefully re-install the install pick-up module. Make sure the leveling arm is not obstructed by the suction tube. Re-install factory lock ring.

Attach both end of the FL-1002 to the Push-Lok fitting of the BHF-1002. Remember to oil the fitting and fuel line. Route fuel line over frame rail when re-installing the fuel tank. Torque tank hanger bolts to proper specifications.

Connect WH-1004 to the fuel module along with the factory fuel lines. Connect factory wire harness to the WH-1004.

Re-attach filler neck and clamps.

FASS Titanium Install 98.5-04 In Tank Lift Pump, 05-12 Dodge Cummins 5.9L, 6.7L Part 4

The FASS Titanium series designed for the 2005-2012 Dodge Cummins 5.9L/6.7 L and the 1998.5-2004 Dodge with in tank lift pump 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 Platinum. 

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

 

Step 4: Install fuel line.

Only use sealant on threads installed into pump assembly.

Route suction line to “T” port. Cut FL-1002 to length. Insert PL-1005 in line using oil. Attach to 10-299. Torque to 18 ft./lbs.

Route fuel line from the "R" fitting of the suction tube assembly to the "R" port on the FASS system with a gentle bend. Cut and insert the PL-1005 fitting to the hose. Use oil. Attach fitting to the "R" port. Torque to 18 ft/lbs. Insert PL-1005 in remaining fuel line. Connect to the "E" port of the FASS system. Use oil. Torque to 18 ft./lbs. Route this line up to the injection pump.

Disconnect factory fuel line from inlet side of the factory injection pump and install the DIPF-1003 fuel fitting. (This is where the fuel line from the fuel filter housing enters the injection pump.) Torque to 18 ft./lbs.

Cut fuel line to length and insert PL-2003 90° (or PL-1005 for 2011) fitting using oil. Attach to DIPF-1003. Torque to 18 ft./lbs.

FASS Titanium Install 89-93 Dodge Cummins 5.9L Part 1

The FASS Titanium series designed for the 1989-1993 Dodge Cummins 5.9L 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 Platinum fuel system. 

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

Step 1: Install electrical harness.

The electrical harness is installed first in order for power to be applied to the pump for lubrication purposes.

Attach WE-1001 to the WH-1002 Wiring Harness. Route WE-1001 red lead through the fire wall using existing grommet.

 

Attach red wire of the WH-1002 to the positive battery terminal using ring terminals. Attach green wire to a clean ground, preferably the negative battery terminal. Secure fuse block in a location protected from outside elements.

Secure Relay in an upright position, as shown, to prevent moisture from entering.

Connect the fuse tap to the hot leg of the fuse.

Using the flag terminal and fuse tap, connect the RED lead of the WE-1001 to the “hot side” of a terminal in the fuse box. It is “hot” when the key is in the on position.

FASS VIP Dealer and Warranty Information

The Fuel Air Separation System (FASS) Fuel Systems product lineup is the conception of a nearly 20-year old Marthasville, Missouri based business aptly named Diesel Performance Products, INC. This manufacturer decided that the best way for customers to receive proper systems with first-rate customer support is to distribute their products using VIP and Authorized Dealers. The only way customers can receive the best service when purchasing FASS products is by coordinating with certified vendors such as FASS VIP Dealer Orange County Diesel. Because we are in the age of the Internet, with aggressive worldwide price checking now a routine action undertaken by modern consumers, the question you may be asking is this: Why purchase only from a certified vendor? Why not purchase it at a cheaper rate from a grey-market vendor who is not officially certified? The answer is simple: FASS only honors its world-class warranty when purchased through vendors FASS approves. Still want the gray-market discount? The following information details the extent of the FASS manufacturers' warranty:

Dodge Direct Replacement Pump Series, 4-Year Warranty.

Duramax Series, 4-Year Warranty.

Heavy Duty Series (Semi-Truck/Class 8), 4-Year Warranty.

Heavy Duty Series (Pickup Truck).

Titanium Series (Semi-Truck/Class 8), 4-Year Warranty.

Titanium Series (Pickup truck), Lifetime Warranty.

Platinum Series, Lifetime Warranty.

Adjustable Fuel Pump, Lifetime Warranty.

Picture this scene: You are a diesel engine user, and the need for a new fuel system is now apparent. You contact the specialists at FASS’s VIP dealer Orange County Diesel in Huntington Beach, California. After precise recommendations from our consultants and some of your own individual thoughts, you came to a decision on a FASS product, and finally purchased the model you needed. In order to qualify for the manufacturer’s warranty, you must follow these steps: 

Complete product registration, attach a copy of your receipt, and mail this information to FASS Fuel Systems, 16240 State Hwy O, Suite B, Marthasville, MO 63357. This relevant warranty information must be received from FASS within 30 days of purchase. If this information is not received within 30 days, FASS will only provide a one-year manufacturer’s warranty from the date of purchase.

If you are proficient with working on your own machine, you are definitely welcome to perform the installation and maintenance on your own, while in the process utilizing FASS' online resources and excellent warranty. However, if you prefer to have an experienced specialist work on your machine, our technicians can install systems in approximately four hours. Periodic service on your water separator and fuel filter usually takes around ten minutes.

Please see the OC Diesel website for the FASS lineup of products. If you have any questions about any FASS product we sell (including the warranty information), feel free to call and speak to a FASS service professional at 714-848-2170.