FASS FA F16 260G User Manual

INSTALLATION MANUAL

APPLICATION:

FA F16 260G (260G @ 8psi)

Ford Powerstroke 6.4L

*bypassing the factory Lift Pump*

2008-2010

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.

 Flush and clean all brass fittings and fuel line from debris.

FA F16 260G

components.

tempting any electrical connections.

FASS Recommended Application

Powerstroke (6.4L) 2008 - 2010 with extreme horsepower modifica-

tions

Serial #

 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 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 [e-mail] 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 F16 260G)

Serial # Found

(FA F16 260G)

Adjustable Fuel Pump Series

260 GPH

8 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

Installation

Fuel Pressure Port

Step 1: Install Electrical Harness
Step 2: Prepare Suction & Return Line
Step 3: Mount Fuel System
Step 4: Install Fuel Line
Step 5: Check/Set Pressure
Step 6: Check Installation

Contents

THB-1001

PFB

2001C

-

FF-3248

BHB-1001

MP-9024

FPB-2005

30 amp Fuse

FL-1002 x9’

WH-1002

Mounting Package Contents

*WE-1006*

BHF-1002

RS-1002

PLB-1238

1 1/2” Washers

10-300

PLB-1212

BHN-1001

PL-1004

LW-1001

Cable Ties

1/2” Plug

PL-1005

Ring Terminal

OR-223

1 Hex Bolt 1/2” -20 x 1 1/2”

HC-1001

ST-1005Px16”

4 1/4 - 20x1.75”

1/4” Nut

RS-2001

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 ring terminals, attach red wire of the WH-1004 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. The use of corrosion preventative spray is

recommended.

B. 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:

C. Route wire harness along frame to the approximate mounting location near the fuel tank. Completion

of this step will be addressed in the 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.

WE-1006

Factory Lift Pump

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. Remove the filler neck and overflow tubes from the truck by loosening the

clamps at both ends.

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.

C. Disconnect factory suction and return lines with the use of a quick discon-

nect tools.

D. With the fuel tank empty of fuel, remove it from the vehicle.

E. Clean the fuel module area then remove the lock ring on the top of the fuel

tank.

F. Once the lock ring is removed, carefully remove pick up module from fuel

tank without bending fuel level arm.

NOTE: Hose clamps are not recommended for push lock fittings.
They will hold up to 300psi! Use oil on fittings and inside fuel line

when installing Push-Lok fittings

G. Assemble the BHF-1002 with the PL-1004 in port “S” using thread tape,

the 1/2” plug in port “R” along with pushing the ST-1005P onto the barb
portion of the BHF-1002,.Insert O-ring into groove. Torque to 40ft/lbs.

H. Before drilling marked location, clean area of debris. Using the photo dou-

ble check area selected for any interference including the fuel level arm.

I. Drill a 1 3/8” hole, catching all debris. De-bur hole and remove any

missed debris in the fuel tank.

J. VERY IMPORTANT: Support fuel tank on both ends allowing the natu-

ral formation of the tank to take place. Failure to perform this step can and
will create an issue with less usable fuel!

K. Place the bulk head assembly into the drilled 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. Using a razor knife, make multi­ple cuts to insure proper length, it is easy to shave the suction tube with the
razor. It is more efficient to cut the tube too long and then correct to

proper length than it would be to cut too short.

L. With proper length being obtained place the assembly into the drilled hole

securing the assembly using the lock washer & nut. Tighten Nut. Loctite
may be applied to the threads of the BHF-1002 for added insurance.

M. Carefully reinstall install pick up module making sure the leveling arm is not obstructed by the suction

tube. Reinstall factory lock ring. Push one end of fuel line onto ‘S’ port of suction tube assy. Route
fuel line over frame. Do not cut at this time. Reinstall fuel tank making sure to reconnect factory lines
and electrical connections. Torque hanger bolts to factory specifications.

Some of the photo’s are of a different application, procedures are the same.

A. Insert PFB-2001C in to bed channel align the nut with the opening on the channel.

.

B. Secure PFB-2002 and RS-2001 with (1) hex bolt 1/2” -20 x 1 1/2” and (1) 1/2” washer to FPB-2005

C. Secure THB-1001 to bolt on bracket with the RS-1002 and the (5)-1/4-20x1 bolts, 1/4 washers, and

1/4 nuts. With the (4)-1/4-20x 1.75” bolts thread the BHB-10001 to the THB-1001.

Note: Use of Anti-seize compound is highly recommended.

D. 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

E. 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.

F. Disconnect the factory power plug to the HFCM lift pump. Clean plug and install the WE-1006 exten-

sion connector. Plug female plug of the WH-1002 harness into pump. Reconnect the battery. Turn
key on. With pump operating, liberally spray WD-40 (or equivalent) into the “T” port. This process
helps lubricate the gear for easier initial priming.

Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly.

A. Using quick disconnect tools, remove the fuel lines from the front of the factory HFCM lift pump. Re-

move the fuel lines attached to the rear of the factory HFCM lift pump by pressing in on the tabs.

B. Install in-line fuel filter in an accessible location in the suction line

using the HC-1001’s. Make sure the arrow is in the direction of the
fuel flow.

Note: Inline filter will need to be replaced every 6,000 miles.

C. Route the fuel line from the ‘E’ port of the FASS to the factory lift

pump’s outlet quick disconnect and cut to length. Insert the PLB-1212
into FASS fuel line using oil. Slide the PLB-1212 into the factory
quick disconnect until you hear a click. Lock down factory retainer
clip. Plug or cap unused factory fittings.

D. Measure between the two factory return fittings. Insert two PLB-1238 fittings into the provided FL-1002

fuel line using oil. Insert fuel line into factory quick disconnects until you hear a click. Lock down re­tainer clip. Secure fuel line and wire harnesses.

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 8 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

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

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