INSTALLATION MANUAL
APPLICATION:
FA D08 095G (95gph @16psi)
FA D08 150G (150gph @ 16psi)
Cummins 5.9L 24 Valve
1998.5-2004
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 Install manual for full Limitations 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.
¡WARNINGs!
Read all instructions before starting installation of this product!
Installing the improper FASS Pump can cause severe engine damage.
Secure vehicle from ROLLING!
Use caution when drilling. Steer clear of any electrical wires , air lines or other damageable
Consult vehicle’s manufacturers’ instructions concerning the electrical system before at-
Be sure that the serial # on this installation manual matches that of the outside of the box.
FA D08 095G
FA D08 150G
Note: If the truck has been retrofitted with an in-tank fuel pump, you must use a suction tube kit
Due to the increase of fuel flow you may encounter a problem with the stock fuel module.
components.
tempting any electrical connections.
FASS Recommended Application
Cummins(24 Valve) 1998.5-2004 with stock - moderate horsepower
modifications
Cummins (24 Valve) 1998.5-2004 with moderate - extreme horsepower
modifications
or return this kit in its new unused condition for a FA D04 095G.
Adding a FASS suction tube kit will solve that.
Serial #
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
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 effi-
ciency. 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 D08 095G or FA D08 150G)
Serial # Found
(FA D08 095G or FA D08 150G)
Adjustable Fuel Pump Series
95 or 150 GPH
16 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
Fuel Pressure Port
‘T’
Fuel Inlet Port
Installation
Step 1: Install Electrical Harness
Step 2: Mount Fuel Pump
Step 3: Install Fuel Line
Step 4: Check/Set Pressure
Step 5: Review Installation
Contents
THB-1001
*Cable Ties*
FF-3270
BHB-1001
MP-9009
FL-1001 x14’
WH-1002
Mounting Package Contents
RS-1002
2 1/4 20x3.5”
10-300
1/4” Nut
FP-1001
PL-1002
1/4” Lock Washer
DIPF-1001
Ring Terminal
NP-1001
PL-1003
QD-1001
4 1/4 20x1.75”
HC-1001
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 ring terminals, attach red wire of the WH-1002 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. Use of corrosion preventative spray is recommend-
ed.
B. Disconnect power source to the factory lift pump.
1998.5-2002
2003-2004
C. Connect the WH-1002 wire harness branch coming from the relay to the factory power source re-
moved in the Step 1b.
D. Secure Relay in an upright position, as shown, to prevent moisture from entering. Di-electric grease
may be applied to prevent corrosion. Examples of locations to secure relay:
E. Route the WH-1002 wire harness along the frame rail to the mounting location of the FASS fuel
pump.
A. Position system to mounting location, drivers side bed rail in front of
the axle. The mounting bracket may be mounted on either side.
Use the mounting template located on the contents page to accurately
mark the mounting location. Drill two 1/4” holes (unit may be
mounted on either side)
B. Place a rubber spacer between the hanger bracket and bed rail
and the other rubber spacer on the opposite side between the bed
rail and NP-1001 nut plate. Install the 2 - ¼”x 3 1/4” bolts, nuts
and lock washers and THB-1001.
C. Using thread tape install the 2 - 10-300 into the “T” & “E” ports.
Torque to 40 ft./lbs. Use of Anti-seize compound is highly recommended.
D. Using the bottom portion of the mounting bracket and the 4 – ¼” –
20 x 1 ¾” bolts, mount the fuel pump mount the pump so the port
labeled “T” is facing the rear of the truck. Torque the 4 - ¼ - 20x 1
¾” 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.
Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly.
A. Using a 3/8” hose clamp install the QD-1001 into the opposite end of
the fuel line addressed in the previous step. Oil o-rings inside Quick
Disconnect.
Helpful Hints: 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
gain you about 3” more working room.
B. 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 addressed in the previous
step. Bed is removed for photo clarity.
C. Connect the male end of the wire harness to the female electrical con-
nector 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: 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
D. Route suction line to port ‘T’. Cut FL-1001 to needed length and con-
nect to 10-300 in port ’T’ using the PL-1002. Be sure to oil both before attaching.
E. 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.
T
Note: Inline filter will need to be replaced every 6,000 miles.
F. Connect remaining fuel line to the ‘E’’ using a PL-1002. Use oil.
Route this line to the inlet port of the factory filter housing.
E
G. Route the fuel line to the inlet port of the factory filter housing. Refer to your vehicles application:
Note: If the truck has had the retrofitted in-tank pump installed, usually installed by a
Dodge Dealer after a fuel lift pump failure, a separate suction tube will need to be installed
in the fuel tank. This retrofit will not allow fuel to be drawn through the FASS pump! Or-
der a STK (Suction Tube Kit) from FASS.
H. Disconnect factory fuel pump from the side of the factory fuel filter using
a 5mm Allen head socket. Keep the Allen bolts and the o-ring from the
inlet port.
I. Assemble the DIPF-1001 into the FP-1001. Reuse the o-ring from the pre-
5 mm bolt
vious step.
J. Insert the Filter Plate assembly in place of the factory fuel pump using 2 of
the 4 Allen head bolts. Torque to 8ft/lbs.
K. Measure and cut fuel line. Insert PL-1003 90° Push-Lok fitting using oil. Install fitting to fuel plate.
Torque to 18 ft/lbs.
Note: Secure all fuel lines with cable ties. Cable ties are an economical way to prevent the
possibility of problems occurring!
These models can have the inlet fitting on top of the filter canister or on the side.
E. Disconnect inlet fuel line to the filter housing. Install DIPF-1003. Torque to
18 ft/lbs.
F. Measure and cut fuel line. Insert PL-1003 90° Push-Lok fitting using oil. Install fitting to DIPF-1003.
Torque to 18 ft/lbs.
Note: Secure all fuel lines with cable ties. Cable ties are an economical way to prevent the
possibility of problems occurring!
E. Disconnect factory fuel line bracket from inlet side of the factory fuel filter
and install the DIPF-1003 injection pump o-ring fuel fitting into this inlet
port.
F. Measure and cut fuel line. Insert PL-1003 90° Push-Lok fitting using oil. Install fitting to DIPF-1003.
Torque to 18 ft/lbs.
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 16 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 pressure.
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 completed
warranty information along with a copy of the purchase receipt in to Diesel Performance Products, Inc.
Att: Warranty 16240 Hwy O Suite B Marthasville, MO 63357
Answer the following questions:
Did the vehicle start fine without the FASS or HPFP? Do you have high mileage on the VP44? If yes,
have your VP44 checked. Has the VP44 been subjected to a PSI of 5 or less? Has the VP44 been subject
to a failing lift pump? Does it occur more frequently when the conditions are warm? Have you recently
replaced your VP44? Was it used?
If yes to any of these questions, Start vehicle as soon as you enter the key (do not wait for the
“wait to start” light to go out) If the vehicle starts it suggest that the problem lies with the VP44.
Is the fuel pressure where it should be?
Has the truck had an ECM re-flash? If not, contact your dealer to find the most current flash for your
truck.
Do you have a WH-1002? If yes, refer to the “WH-1002” section located in “Electrical”
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
THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND UNDER-
STANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.
LESS SHIPPING.
Technical Support:
Diesel Performance Products, Inc.
16240 State Hwy O Suite B
Marthasville, MO 63357
636-433-5410
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