INSTALLATION MANUAL
APPLICATION:
FA C09 220G (220gph @ 10psi)
Duramax 2500 & 3500
2001-2015
Dear Valued Customer,
“Made in the USA” is not just a slogan at FASS; it’s what we live by! FASS is not only
assembled in the USA but 98%+ of the FASS product is manufactured in the USA, helping to employ Americans and strengthen America. At FASS, we scrutinize our suppliers and demand the
highest quality American-made components. However, this does come at a price, which is one of
the main reasons FASS products are more expensive than the competition. Remember price does
not dictate quality but quality does dictate price! Here at FASS, we believe it’s worth the commitment and will continue this practice to support America! Our competition is doing exactly the opposite by using foreign-made components.
Building extremely “High-Quality” fuel products is our business. We concentrate all of our
efforts in this arena. No one else is as specialized as FASS in what we do! This is one of the ingredients to insure you are running with the “Highest-Quality” fuel system in the world! We have implemented very rigorous testing procedures to provide the “Highest Quality” we have become
known for. Not only is our product superior, but customer satisfaction is #1 at FASS. It is our goal
to provide the best service possible. Our confidence is evident in the products we make as each
product is backed by an industry leading warranty!
Our R & D department, in conjunction with our Dealer Support department, is continually
searching for ways to improve quality, expand our product line, and provide superb support to our
network of dealers so our customers’ needs and expectations will be exceeded.
To help insure you receive the proper system and customer support at the local level, FASS
has a VIP and Authorized Dealer network representing FASS products. This is one reason you
must purchase through a dealer to comply with our warranty policies. If you do not, there is no
warranty! We recommend you go to www.FASSride.com, click “Find A Dealer”, put in their ZIP
code, select the type of dealer, and see if the company you purchased from is listed. If they are not,
put their phone number in the field below the ZIP code field to see if they are listed. Below these
two fields is a list of “Terminated/Unauthorized” dealers. You may want to review this list. If the
company is not listed or is on the “Terminated/Unauthorized” list, we suggest you return the product immediately to that dealer and call FASS. We’ll recommend you to the nearest dealer.
VERY IMPORTANT: Make sure to fill out your product registration form and return the
original form to FASS Fuel Systems within 30 days of purchase accompanied with a copy of the
purchase receipt. Complying with these guidelines will qualify you for the Extended Warranty!
See the back of Installation Manual for full Limitation of Warranty. In the event that the
buyer does not agree with this agreement: the buyer may promptly return this product, in a new and
unused condition, with a dated receipt, to the place of purchase within thirty (30) days from date of
purchase for a full refund less shipping.
The installation of this product indicates that the buyer has read and understands the
Limitation of Warranty agreement and accepts its terms and conditions.
3
¡WARNINGS!
Read all instructions before starting installation of this product!
Installing the improper FASS Pump can cause severe engine damage.
FA C09 220G
Secure vehicle from ROLLING!
Use caution when drilling. Steer clear of any electrical wires , air lines or other damageable
components.
Consult vehicle’s manufacturers’ instructions concerning the electrical system before at-
tempting any electrical connections.
Be sure that the serial # on this installation manual matches that of the outside of the box.
Flush and clean all brass fittings and fuel line from debris.
Keep debris from entering the internals of the system during installation. Getting debris in
FASS Recommended Application
Duramax 2001-2014 with super extreme horsepower modifications
Serial #
the “T” port can lock up the motor. If the motor does lock up from debris call FASS for
technical assistance.
Be sure to utilize the inline fuel filter included in this kit, or the equivalent, to prevent a
motor lock up.
Wear safety glasses when operating power tools such as drills and grinders or when using a
punch or chisel.
Properly secure lines to prevent chaffing.
INSTALLATION MANUAL
Follow these steps to ensure a simple installation of your new
FASS ADJUSTABLE FUEL PUMP
1. Read the installation manual completely before attempting installation. The instal-
lation of this product indicates that the buyer has read and understands the limita-
tions of the FASS manufacturers warranty agreement and accepts the responsibility
of its terms and conditions.
2. Inventory the package components. Notify the place of purchase immediately of
any parts missing or damaged.
3. The installation recommendations contained herein are guidelines. Use good judg-
ment and take into consideration your vehicles' accessories.
4. For best results in accuracy and efficiency (due to training, communication, and our
relationship with our dealer network), we recommend a ViP FASS dealer for the
installation. They are prepared to install the FASS fuel pumps with the most efficiency. If a situation/problem arises during the installation, they are the most pre-
pared for that situation/problem. DPPI is not responsible for any installation mis-
takes.
5. If you have any questions or concerns that can not be addressed with your dealer,
email or call FASS.
6. If any installation procedure is uncertain, contact FASS technical support.
Email techsupport@FASSride.com with the following information:
Your Name, address and daytime phone number
Model
Serial Number
Last 6 of vehicles’ VIN
Date of purchase
Nature of Your Concern
Call customer service; 636-433-5410 with the following information:
Model
Serial Number
Last 6 of vehicles’ VIN
Date of purchase
(FA C09 220G)
Serial # Found
(FA C09 220G)
Adjustable Fuel Pump Series
220 GPH
10 PSI (Approximately)
A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage!
Adjustment Lock Nut
Set screw
Boost
Compensation
Port
“E”
To Engine
‘T’
Fuel Inlet Port
Installa-
Fuel Pressure Port
Step 1: Install
Electrical Harness
Step 2: Prepare Suction & Return Lines
Step 3: Mount Fuel System
Step 4: Install Fuel Line
Step 5: Check/Set Pressure
Contents
THB-1001
FPB-2005
FF-3248
BHB-1001
MP-9038
FL-1002 x14’
WH-1006
Mounting Package Contents
*Cable Ties*
46044
RS-1002
PL-1005
BHF-1002
10-300
1/2” Plug
PL-1004
QD-1002
Ring Terminal
ST-1005Px16”
46260
4 1/4 - 20x1.75”
BHN-1001
1/4” Nut
LW-1001
RS-2001
OR-223
HC-1001
1/4” washer
2 1/4 - 20x1.5”
The installation of the electrical harness is done first, allowing power to be applied to the pump for
lubrication purposes later in the installation.
A. Using wire stripping tool remove excess insulation off the add-a-fuse
and the WH-1006.
B. Place wire from 46044 and WH-1006 into butt connector. Using crimping tool connect 46044 and WH-
1006 with butt connector. Install 46260 to 46044 bottom slot (opening that is near the spade).
C. 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. The use of a corrosion preven-
tative on electrical connections is recommended.
D. Secure relay and fuse in an upright position, as shown, to prevent
moisture from entering. Di-electric grease may be applied to prevent
corrosion.
RELAY
FUSE
E. If fuse panel is located in the cab it will be necessary to guide the single
red wire from the relay through the fire wall grommet to access the fuse panel.
F. Locate fuse box under hood and select ignition hot fuse. Remove fuse and put Add-A-Fuse in place.
Install fuse previously removed. The use of a corrosion preventative on electrical connections is
recommended.
G. Route WH-1006 wire harness along frame rail to mounting location of pump. Completion of this step
will be addressed in the Mounting Step 3.
Note: The FASS harness provided has a 15 amp fuse and the 30 amp fuse provided
loose in the kit is to be installed on the wiring harness due to the volume and torque
the FASS pump is producing.
Some of the photo’s are of a different application, procedures are the same.
A. Very Important: 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!
B. If necessary, carefully bend the sheet metal down that is cov-
ering the side.
C. This step can be omitted on 2011– models. Remove the 3 bolts holding the fuel cooler to the mount-
ing bracket. The fuel cooler is located in front of the fuel tank.
D. Using a fuel line disconnect tool, disconnect the factory suction line 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. Pinch in tabs on 2011- models.
2011-Present
E. Remove filler neck tube and over-flow tube from the top of the
fuel tank by loosening clamp. Some models have an integrated
filler neck. If your over-flow is integrated, be careful not to hang
up the internal flow tube when lowering the tank.
Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly.
F. Disconnect electrical harness. Using disconnect tools, remove factory suction & return lines from fuel
module. Pinch in tabs on 2011-. Disconnect overflow tube. You can now remove the fuel tank.
G. Check fuel tank for good installation location of the suction tube assembly. Remove the lock ring on
top. Mark location of Fuel Module in relation to the tank. Remove Fuel Module. Be careful not to
bend the Fuel Level Arm.
H. Using a cup, reach inside the tank under the hole location to catch debris. Drill a 1 3/8” hole. Re-
move debris from top of tank. Use blocks or something similar to support tank during measure-
ment simulating tank “hanging” by the straps. Failure to do so may result in a short draw tube.
NOTE: Hose clamps are not recommended for push lock fit-
tings. They will hold up to 300psi! Use oil on fittings and inside
fuel line when installing Push-Lok fittings
I. Assemble the BHF-1002 with the PL-1004 in port “S” using thread
tape, the 1/2” plug in port ‘R’. Torque to 40ft/lbs. Push the ST1005P onto the barb portion of the BHF-1002. Insert O-ring into
groove.
J. Place the suction tube assembly into the hole. Take measurements so
the bottom of the suction tube is only 1/8” (no more than 2 quarters
stacked) from the bottom of the fuel tank. Before cutting the suction
tube, triple check the measurements. It is more efficient to cut the
tube too long and then correct to proper length than it would be to cut
too short.
K. With proper length being obtained with the suction tube, de-bur and
flush assembly. Slide tube through hole, lock washer, and nut. Make
sure O-ring on bottom of bulkhead fitting remains in it’s groove.
With BHF-1002 properly seated against tank, tighten nut.
L. Carefully re-install pick up module. Do not bend Fuel Level Arm.
M. Attach fuel line to Push-Lok fitting. Remember to oil the fitting and
fuel line. Route fuel line over frame rail when reinstalling fuel tank.
N. Reinstall fuel tank. Remember to reconnect factory suction line, return line and electrical harness.
Torque tank hanger bolts to proper specifications. Reattach filler neck and clamps.
A. Locate bed bolt and remove the bolt. Position RS-2001 between FPB-2005 and truck bed.
B. Secure THB-1001 to bolt on bracket with the RS 1002 and the (2)– 1/4-20x1 bolts, 1/4 washers, and 1/4
nuts. With the (4)-1/4-20x1.75” bolts thread the BHB-1001 to the THB-1001.
Note: Use of Anti-seize compound is highly recommended.
C. Using thread tape, install the 2 10-300 into the “T” & “E” ports. Torque to 40 ft./lbs. Connect the male
end of the wire harness to the female electrical connector on the FASS pump. Reconnect the battery.
Turn key to the “On” position. With the FASS pump on, squirt a liberal amount of WD-40 or other
lubricant into the “T” port. This procedure will “wet” the Gerotor and allow for better suction during
initial priming. Note: Do Not Put Thread Tape on Flare of Fitting
D. Slid the FASS pump into mounting brackets with the weep hole facing down. Torque (4) bolts to 110
inch pounds.
VERY IMPORTANT: REMEMBERING THE POSITION OF THE “T” PORT, THERE IS A SMALL WEEP HOLE IN
THE BASE DIRECTLY NEXT TO THE ELECTRIC MOTOR, THIS HOLE MUST AIM DIRECTLY TO THE
GROUND!! IMPROPER INSTALLATION OF THE PUMP CAN CAUSE PREMATURE WEAR AND VOID MANUFACTURES WARRANTY.
A. Route suction line from Step 2L to port ‘T’. Cut FL-1002 to needed
length. Using oil, insert PL-1005 and connect to 10-300 in port ’T’.
Torque to 18 ft./lbs.
B. Install in-line fuel filter in an accessible location in the suction line
using the HC-1001’s. Making sure the fuel flow travels the direction
of the arrow on the canister.
Note: Inline filter will need to be replaced every 6,000 miles.
C. Using oil, insert PL-1005 into FL-1002 fuel line. Connect to the ‘E’
port of the FASS pump. Torque to 18 ft./lbs. Measure fuel line to the
factory feed line disconnected in Step 2c and cut.
D. Using an HC-1001 hose clamp, insert the QD-1002 into the other end of the provided FL-1002 fuel line
and secure. Oil the rings inside the QD-1002 and slide over the factory feed line until you hear a click.
Cap factory suction line and secure.
2001-2010
E. Reassemble fuel cooler on 2001-2010 models.
2011-Present
F. Carefully re-bend sheet metal back to original shape to protect
fuel tank, if needed.
G. Re-install driveshaft
Note: Secure all fuel lines with cable ties. Cable ties are an economical way to prevent
the possibility of problems occurring!
The preset pressure is approximately 10 psi. Follow these steps to check or reset the fuel pressure. The port
with 1/8” Allen plug marked with the letter “P” is your fuel pressure port. Exceeding factory fuel pressure
may result in severe engine damage. Consult with engine manufacture before adjusting pressure!
With the pump running –
Loosen the lock nut
Turn the adjustment screw clock wise to increase pressure and counter clock wise to decrease pres-
sure.
Once desired fuel pressure is obtained, tighten lock nut.
Blow out any open lines/cover any open ports
Bolts and fasteners properly tightened?
Electrical harness and fuel lines secured and properly tightened?
Has the system been primed?
1. Turn key to the ignition position, turning on the FASS pump for 15 sec..
2. Crank engine and allow to run for at least 1 minute.
Check for leaks.
Start the engine
Recheck all fluid and filter connections for leaks
This pump comes with a 1 Year Manufacturer’s Warranty based on the date it has been manufactured.
To receive your extended Lifetime Warranty, you have 30 days from date of purchase to send the com-
pleted warranty information along with a copy of the purchase receipt in to Diesel Performance Prod-
ucts, Inc. Att: Warranty 16240 Hwy O Suite B Marthasville, MO 63357
Disclaimer: To help insure you receive the proper system and customer support at the local level, FASS has a VIP and
Authorized Dealer network representing FASS products. This is one reason you must purchase through a dealer to comply
with our warranty policies. If you do not, there is no warranty! We recommend you go to www.FASSride.com, click “Find
a Dealer”, put in their ZIP code, select the type of dealer, and see if the company you purchased from is listed. If they are
not, put their phone number in the field below the ZIP code field to see if they are listed. Below these two fields is a list of
“Terminated/Unauthorized” dealers. You may want to review this list. If the company is not listed or is on the
“Terminated/Unauthorized” list, we suggest you return the product immediately to that dealer and call FASS. We’ll recommend you to the nearest dealer.
Diesel Performance Products, Inc. (hereafter “SELLER”) gives Limited Warranty as to description, quality, merchantability,
fitness for any product’s purpose, productiveness, or any other matter of SELLER’S product sold herewith. The SELLER
shall be in no way responsible for the product’s open use and service and the BUYER hereby waives all rights other than
those expressly written herein. This Warranty shall not be extended or varied except by a written instrument signed by
SELLER and BUYER.
When MANUFACTURER receives the “ORIGINAL” PRODUCT REGISTRATION form with a copy of the “BILL
OF SALE/SALES RECEIPT” within 30 days of the sale, then the following applies! The Warranty will then and only
then be validated to that of which typically accompanies your unit for your specific application from the date of sale or for
recommended service life and limited solely to the original purchaser and/or vehicle and parts contained within the product’s
kit. This warranty does not cover normal wear on consumable items such as but not limited to filters, fuel line, wire harness
& etc. The warranty does not cover seized gears due to lack of filtration or fatty acid build up on the gears. Returned items
will arrive prepaid to the place of purchase. Diesel Performance Products, Inc. will repair, without cost, any product found to
be defective during the warranty period; parts only, or at its option, will replace such products in exchange for the product.
Repair or replacements are warranted for the remainder of the original warranty period. All Warranty claims are subject to
approval by Diesel Performance Products, Inc.
A Return Material Authorization (RMA) number must be obtained before any product is to be returned to Diesel
Performance Products, Inc. for warranty consideration, repair or product return. Requests for product returns must be
offset by an equal value order. Return parts must be completed and in resalable condition. No returns after 30 days.
The following information is required to obtain a RMA number before returning product:
Your Name, Address, and Phone Number’s
Model and Serial Number (Not Motor Number) Example: Model HD Series, Serial: 00125966
VIN Number of Vehicle
Date of Purchase
Nature of Problem
RMA and Product Serial Number must be on all paperwork and correspondence. Failure to obtain the required information
or paperwork will result in $25.00/item penalty and delay or denial of any warranty claim.
Under no circumstances shall the SELLER and/or MANUFACTURER be liable for any labor charged or travel time incurred in diagnosis for defects, removal, or reinstallation of this product, or any other contingent expenses.
Under no circumstances shall the SELLER and/or MANUFACTURER be liable for any damage or expenses insured by
reason of the use or sale of any such equipment. This warranty does not apply to products which Diesel Performance Products, Inc. has determined to have been misused or abused, improperly maintained by the user, or where the malfunction or
defect can be attributed to the use of non-genuine Diesel Performance Products, Inc. parts.
IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT: THE BUYER MAY PROMPLY
RETURN THIS PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF OF PURCHASE, TO
THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM DATE OF PURCHASE FOR A FULL REFUND
LESS SHIPPING.
THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND UNDER-
STANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.
Technical Support:
Diesel Performance Products, Inc.
16240 State Hwy O Suite B
Marthasville, MO 63357
636-433-5410
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