FASS Titanium Install Class 8 Part 3

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 3 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, Part 4, and Part 5 here.

Step 3: Identify fuel line configuration.
Fuel lines older than six-years old (excluding nylon type fuel lines) should be replaced due to interior lining deterioration. This condition can cause problems including fuel starvation, uneven fuel tank levels, etc.

There are three common types of fuel systems.

1. Double-Draw/Double Return Line System, found on most trucks built from 1994-present.
The FASS FLK-S03 fuel line kit has the necessary components for this installation.

2. Single-Draw / Single Return Line System, found on trucks built before 1994 (except for the 359 Peterbilt).
The FASS FLK-S02 fuel line kit has the necessary components for this installation.

3. The 359 Peterbilt has this fuel system: Single Draw Out of Cross-over Fuel Line/Single Return Line System.

If you have this semi-truck, it is recommended to convert to a duel tank system (either a complete Double-Draw/Double Return Line System or a true Single Draw/Single Return Line System.)

Two other popular Class 8 trucks are the Mercedes 4000 Series and the Volvo D12-D15. Both types have the similar return line systems (both are double-draw/double return). However FASS FLK-S04 has the Mercedes' components, and the FLK-S05 has the Volvo's.

FASS Titanium Install Class 8 Part 2

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 2 of a model-specific five-part series about how to install a FASS Platinum fuel system.

Please find the links to Part 1, Part 3, Part 4, and Part 5 here.

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 1

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 1 of a model-specific five-part series about how to install a FASS Platinum fuel system.

Please find the links to Part 2, Part 3, Part 4, and Part 5 here.
 
Step 1: Install Electrical Harness
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 are made.

The particulars of Step 1 differ depending on the type of Class 8 machine you have. The directions presented in blue indicate the parts of the procedure where the steps differ.

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.

Connect WE-1001 wire extension to the WH-1005.

Route red wire/loom of the wire harness through the grommet in the firewall to the ignition or fuse panel.

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

Install the Hobbs Oil Pressure Switch in the oil gallery. Using the spade/ring terminals, connect the green wire of the wire harness to the negative post and the red wire to the positive post of the battery.

Secure relay in an upright position, preferably on the firewall out of the weather. Properly secure all electrical leads and harness.

FASS Titanium Install 06-12 Chevy Duramax 2500, 3500 Part 2

The FASS Titanium series designed for the 2006-2012 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 Platinum fuel system.

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

The 2006-2010 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 06-10 installation are in blue.

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.

Mark location for the FASS Return Manifold on the factory filler neck.

Cut marked location, then position RM-1004 with the 1/2" junction pipe aiming to outside of bed.

Clamp rubber and RM-1004 using both HC-1004's.

FASS Titanium Install 06-12 Chevy Duramax 2500, 3500 Part 1

The FASS Titanium series designed for the 2006-2010 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 Platinum fuel system.

The 2006-2010 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 06-10 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 extension through the fire wall grommet to the fuse panel.

Guide the single red wire from the relay to the engine bay 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 Titanium Install 06-12 Chevy Duramax 2500, 3500 Part 3

The FASS Titanium series designed for the 2006-2012 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 Platinum fuel system.

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

The 2006-2010 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 06-10 installation are in blue.

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 110 in/lbs.

Choose a bracket that best fits your application: the FB-1006 is typically used for short-bed applications, conforming to the front side of the leaf spring mount.

The FB-1007 is typically used for long-bed applications, conforming to the inside of the leaf spring mount.

Assemble the FASS pump brackets using the RS-1001 spacer between.

Hold pump up to the mounting location for rough fitting. FB-1006 is shown.

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.

Before mounting into position, finish connecting wire harness. Using the 3/8" bolts and nuts, secure the bracket to the previously drilled location.

Plug female connector of the FASS harness into pump. Turn key to “on”. With pump operating liberally spray WD-40 (or equivalent) into water separator nipple lubricating Gerotor.

Mount pump assembly to the FB-1001 and secure with 3/8” bolts. Make sure the RS-1001 spacer is used between the brackets.

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

FASS Titanium Install 06-12 Chevy Duramax 2500, 3500 Part 4

The FASS Titanium series designed for the 2006-2012 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 Platinum fuel system.

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

The 2006-2010 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 06-10 installation are in blue.

Step 4: Install fuel line.

Route suction line from Step 2d to the "T" port. Cut FL-1002 to length. Insert PL-1005 in line using oil. Attach to 10-299. Torque to 18 ft./lbs.

Measure FL-1002 from the factory feed connection to the "E" port of the FASS system. Cut and insert PL-1005.

Measure FL-1002 from the factory feed connection to the "E" port of the FASS system. Cut and insert PL-1005.

Connect to the 10-298 in the "E" port of the FASS system. Torque to 18 ft./lbs.

Using oil, insert a PL-1005 into the remaining fuel line. Connect to the "R" port fitting on the FASS system. Torque to 18 ft./lbs. Route this line in a gentle bend to the Return Manifold. Slide over return tube and secure with HC-1001 clamp.

Using oil, insert a PL-1005 into the remaining fuel line. Connect to the "R" port fitting on the FASS system. Torque to 18 ft./lbs. Route this line in a gentle bend to the Return Manifold. Slide over return tube and secure with HC-1001 clamp.

Reattach the 3 bolts holding the fuel cooler to the mounting bracket. Re-install drive shaft.