FASS kit includes: FASS Pump, Filters, Mounting Bracket w/ bolts, Fuel Line, Fuel Fittings, Splicing Tube, Electrical line with sensors...all the parts you need!
What you WILL need: Pipe Thread.

For those of you who who don’t usually need directions, we suggest that you have your “significant other” or close friend read the directions and dictate them to you. We discovered this works best for us. Of course, being who I am, the names for parts such as “1/2’’ return manifold” and “3/8’’ fuel line” turned into “the black thing that looks like a pipe” and “the long blue cord.”

Before doing anything, we put the fuel pump bracket on the FASS System using the five washers and 1/4’’ mounting bolts. The holes lined up correctly, and the washers went between the system and the black thing... I mean the fuel pump bracket. Andy’s FASS System had three washers thicker than the other two so that the bracket would lay flat, however, some of the systems may have five washers the same size depending on the system.

Once that was done, we used thread tape to put one of the 3/8’’ +1/2’’ (push lock + mpt) fittings into the port on the FASS System labeled with the letter “T” and the other on the letter “E.” The 3/8’’ +1/2’’ (push lock + female flare) fitting was to go on the already existing fitting on letter “R” so naturally, I obliged and let Andy know that the white stuff goes on the fat screw and then goes where the “R” is. Note: The neighbor guy has the thread tape.

Getting started on working on the vehicle was one of the trickiest parts of the whole process. The task was to simply disconnect the factory suction line and clip. All you have to do is squeeze the two tabs on the top part of the hose together at the same time and then pull it off the big round thing. Seems easy enough, right? Maybe not. I watched many attempts at it, but ultimately, it turns out that there is a need for a sidekick every once in a while. I put the quick disconnect fitting and the 3/8’’ hose clamp on the fuel line and replaced the factory suction line.

Taking the filler neck tube off of the truck was easy after the trouble we had gone through before. The scary part was cutting it in half so that the return manifold could go in the middle of it. We secured it with the 1-3/4’’ clamps and reinstalled the filler tube with the junction pipe pointing towards the outside the bed of the truck. The other end of the fuel line goes on the junction pipe of the return manifold with a 3/8’’ hose clamp.

The next step was mounting the system. We used the “L” shaped bracket to mark the two holes we needed to drill into the bed support of the truck. It took two 13/32 holes to drill the holes and the two 3/8’’ bolts and flanged nuts to mount the “L” to the truck. The four 3/8” bolts and flanged nuts secured the system to the “L” bracket. We oiled the o-rings on the filters, put those onto the system, and just like magic, there’s a FASS Fuel System in your truck and ready to go! Or not.

The fuel line from the suction port goes to the port of the FASS System labeled “T,” and the fuel line from the return manifold goes to the port labeled “R.” So we cut those to the correct length, oiled them, and put them on the fittings. Andy had to do that one on his own. It took some muscle. So then there was all that left over fuel line. One end of it got oiled and connected to the letter “E” port, and the other was to go up into the hood.

A glass of iced tea and a couple of oil spills later, we routed the rest of the fuel line up the frame of the truck so that it reached the injection pump under the hood. Once Andy disconnected the factory fuel line from the inlet side of the factory injection pump, he used oil to attach the 3/8’’ +3/8’’ (push lock + female flare) fitting to the fuel line. We attached that fitting to the injection pump and torqued it to 18ft lbs.

All that was left was installing the electrical harness. To me, it didn’t matter what any of it was called. All I knew was where it should plug in. Needless to say, I made sure Andy knew as well. It’s a long cord with one plug-in on one side and two plug-ins branching off of the other end. The single plug-in went to the electrical connecter on the FASS System itself. The other end went up into the hood like the fuel line. One plug-in had green and red wires coming from it. Those were to connect to the battery using the ring terminals. Before plugging in the last part of the electrical harness, we had to disconnect the power source to the factory pump lift(It was next to the gray circle thing). Then all we had to do was plug the FASS System’s wire harness (WH-1002) into the factory power source. Wire ties were crucial throughout this entire process.

Tuning the filters was easy. We just turned the ignition on for a little while, tried to start the engine, and then let it turn off. We could hear the filter working then. We did this a few more times and then started the engine shortly after we let it turn off so that the filters were still running. I knew how to do it all, of course, but it’s good to let others learn for themselves sometimes. ;D

Andy's Notes

After installing the FASS, I definitely noticed better fuel delivery. I notice much better throttle response and it seems that my truck starts a hair quicker and easier than it did before. It feels like my truck has enough fuel to keep up with all the high performance mods that I put on it now. The installation was not that bad, but I definitley could not have accomplished the installation withough "The SideKick". My dad and I worked on getting the fuel line off the fuel tank for an hour and a half. Finally, my dad had to leave to go to work and I was about to give up. Nichelle(The SideKick), got under there for 2-3 minutes and got it off. I must admit, when she got under there I probably thought to myself, "Thats cute, but she doesnt have any muscles". Well, what a shocker when she actually pulled the thing off. My Jaw probably dropped(inside of me of course).

I definitely recommend getting the FASS for your diesel pickup. It\'s just another tool that I believe will help prolong the life of your engine and probably your Injection Pump as well. If you have any questions, please contact Diesel_Dan in the Diesel Performance Products/FASS Forum: FASS FORUM