FASS Titanium Install 99-04 Ford Powerstroke 6.0L, 7.3L Part 1

The FASS Titanium series designed for the 1999-2004 Ford Powerstroke 6.0L/7.3L 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.

The red wire of the WH-1001 wire harness will travel through the rubber grommet in the firewall, or into the fuse panel in the engine compartment.

Use a test probe to locate the hot side of the circuit in the fuse block. Connect the fuse tap to the hot side of the fuse.

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.

Green wire must be connected to a clean ground (preferably to the negative battery terminal) without being exposed to any corrosion, preferably the negative battery terminal. Secure fuse block in a location protected from outside elements. Route wire harness along frame rail to the mounting location of pump.

FASS Titanium Install 99-04 Ford Powerstroke 6.0L, 7.3L Part 2

The FASS Titanium series designed for the 1999-2004 Ford Powerstroke 6.0L/7.3L 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

Please be sure that there is enough tube on each side of the cut to insert the RM-1002 and to place the hose clamps.

Mark location on the filler tube that allows you to install RM-1002. Cut tube.

Position RM-1002 with the junction pipe aiming to outside of bed. Connect rubber and RM-1002 using both HC-1004's. However, please do not tighten.

Connect FL-1001 to the junction of RM-1002 using a HC-1001.

Disconnect the factory suction line by pinching in on the side tabs. Be sure to thoroughly clean the suction port.

Insert QD-1001 and clamp into opposite end of fuel line. Oil O-rings inside QD-1001. Slide onto factory suction port until a click is heard. Loop fuel line over frame. Do not cut at this time.

FASS Titanium Install 99-04 Ford Powerstroke 6.0L, 7.3L Part 3

The FASS Titanium series designed for the 1999-2004 Ford Powerstroke 6.0L/7.3L 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.

Placing the RS-1001 between the FB-2001 & the BR-2001, assemble the FASS pump brackets together. Hold pump up to the mounting location for rough fitting.

Position the pump assembly at the mounting location (emergency brake cable bracket) and check for fit. Once location is established, use the mounting template on back of manual to accurately mark drill points.

Route wire harness along frame rail to mounting location. Plug female plug of the FASS harness into pump. Turn key to "on." With pump operating, liberally spray WD-40 (or equivalent) into "T" port.

Pre-drill holes. Final drill with 3/8” bit. Mount pump and tighten all bolts.

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

FASS Titanium Install 99-04 Ford Powerstroke 6.0L, 7.3L Part 4

The FASS Titanium series designed for the 1999-2004 Ford Powerstroke 6.0L/7.3L 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 fuel system.

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. Hose clamps are not recommended for push lock fittings, as they will hold up to 300psi. Also, use oil on fittings and inside fuel line when installing Push-Lok fittings.

Route suction line to "T" port. Cut FL-1001 to length. Insert PL-1002 using oil. Attach to 10-299 in "T" port. Torque to 18 ft./lbs.

 



Route fuel line from the return manifold to the "R" port of the FASS. Cut to needed length, insert PL-1002 using oil, and connect return line to the "R" port. Torque to 18 ft./lbs. Insert PL-1002 into remaining fuel line using oil. Connect fuel line to "E" port. Torque to 18 ft./lbs. Route fuel line to factory lift pump.

If you have a 1999-2002 7.3L, remove inlet fuel line to factory fuel pump. Route fuel line from "E" port of the FASS system to inlet of factory fuel pump. Cut to length. Slide clamp and fuel line over the inlet of the factory fuel pump. Tighten.

If you have a 2003-2004 with 6.0L Powerstroke, using a 3/8" hose clamp, install the QD-1001 into the fuel line. Oil O-rings inside Quick Disconnect.

Pinch in tabs of the inlet fuel line fitting and remove the inlet fuel line from the factory lift pump. Slide QD-1001 onto inlet fuel port of factory lift until a click is heard.

FASS Titanium Install 89-93 Dodge Cummins 5.9L Part 4

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 4 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 3 here.
Step 4: Install fuel line.

Route suction line to port "T." Cut FL-1001 to needed length and connect to 10-299 in port ‟T‟ using the PL-1002. Oil both before attaching.

Route fuel line from the Return Manifold in the filler neck to the “R” port on the FASS system with a gentle bend. Cut and attach the PL-1002 fitting to the hose. Use oil. Attach fitting to the “R” port. Do not use any sealant. Torque to 18 ft/lbs. Connect remaining fuel line to the “E” port of the FASS system using a PL-1002. Use oil. Route line up to VE Injection pump. Do not cut at this time. Connect the WH-1001 Wire Harness to the plug on the FASS system and route with fuel line to the engine bay.

Remove the tension spring. Remove inlet fuel line to VE Pump. Remove the adapter nut below that. If you want to remove this line from the system, remove outlet feed on the factory filter housing, feed the line forward and twist as you pull it through. Be sure to plug the open port on the filter housing.

Install DIPF-1001 Diesel Injection Pump Fitting. Torque to 18 ft./lbs. Measure fuel line to the inlet port. Install PL-1003 90° Push-Lok into fuel line using oil. Attach PL-1003 to the DIPF-1001. Torque to 18 ft./lbs. Re-install tension spring.

FASS Titanium Install 89-93 Dodge Cummins 5.9L Part 2

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 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.

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.

Position RM-1003 with the 3/8” junction pipe aiming to outside of bed. Clamp rubber and RM-1003 using both HC-1004‟s and factory clamps.

Using a HC-1001 connect FL-1001 Fuel Line to the junction of RM-1003. Using a 3/8” hose, clamp install the QD-1001 into the opposite end of the fuel line.

Disconnect factory suction line clip by pressing in on the two tabs located on either side in the connection fitting. Once removed, clean the suction tube and connect the QD-1001. Loop fuel line over frame. Plug or seal factory line or remove.

FASS Titanium Install 89-93 Dodge Cummins 5.9L Part 3

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 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 “T” port.

Attach BR-2001 to back of system using 5 1 1/4” Hex bolts and WA-2001 spacers. Torque to 110in/lbs. Use the Hex Bolt 1/4”-20x2 1/4”+WA-1001D spacers on top of the WA-2001 spacers if you need more space between pump and the frame.

Position system to mounting location, drivers side below the bed in front of the axle. Make sure to mark these drill points at least 1” from radial bend of the frame. The radial bend is both the top and bottom of the frame. Note that there is a wire harness on the opposite side of frame rail.

Drill 4 pilot holes. Then drill those holes out with a 5/16” bit for the self-threading bolts.

Before mounting in position, route wire harness along frame rail to mounting location connecting to FASS. Turn key on. With pump operating, liberally spray WD-40 (or equivalent) into “T” port lubricating gear. Using the 4 - 3/8” Self Threading bolts, attach the pump to the frame. Make sure to place the rubber isolator between the frame and bracket.

Apply motor oil to O-rings located on filters. Attach to system. Tighten by hand.