FASS FA F17 200G User Manual

INSTALLATION MANUAL

APPLICATION:

FA F17 200G (200gph @ 55psi)

Ford Powerstroke 6.7L

*bypassing the factory Lift Pump*

2011-2012

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.

¡WARNINGS!

 Read all instructions before starting installation of this product!

 Installing the improper FASS Pump can cause severe engine damage.

FA F17 200G

 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

Powerstroke (6.7L) 2011 - 2012 with 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 [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 F17 200G)

Serial # Found

(FA F17 200G)

Adjustable Fuel Pump Series

200 GPH

55 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 Line
Step 3: Mount Fuel Pump
Step 4: Install Fuel Line
Step 5: Check/Set Pressure
Step 6: Check Installation

Contents

THB-1001

MP-9071

FF-3248

BHB-1001

FPB-2005

FL-1002 x9’

WH-1005

Mounting Package Contents

46044

RS-1002

RVC-38

DB-4646

10-300

PLB-1212

BHF-1002

PL-1004

*WE-1001*

Cable Ties

1/2” Plug

RVC-12

PL-1005

Ring Terminal

BHN-1001

1 Hex Bolt 1/2” -20 x 1 1/2”

1/4” Nut

4 1/4 - 20x1.75”

LW-1001

1 1/2” Washers

RS-2001

OR-223

HC-1001

ST-1005Px16”

46260

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 46044 and

the WE-1001.

B. Place wire from 46044 and WE-1001 into butt connector. Using crimping tool connect 46044 and WE-

1001 with butt connector. Install 46260 to 46044 bottom slot (opening that is near the spade). Route
46044 lead through the fire wall using existing grommet.

C. Crimp the ring terminals to the red and green wires of the WH-1005 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

The installation of the electrical harness is done first, allowing power to be applied to the pump for

lubrication purposes.

E. Connect the WE-1001 Extension to the WH-1005’s shorter relay branch. Route the extension to the

engine bay fuse panel. Remove a fuse (maximum of 10A) that is “hot” when the key is on. Example:
#54 or #55. Use a test probe to locate the “hot side” of the circuit in the fuse block. Install the fuse
tap into the open location. Install the pulled fuse into the open space on the fuse tap. Disconnect the
vehicles’ battery and continue installation.

56

F. Route WH-1005 wire harness along frame rail to mounting location of pump. Completion of this step

will be addressed in the mounting step.

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

Helpful Hint: Directions for removing factory lines.

1. Pull up on the locking tab (either blue or yellow),

2. Push in slightly on the connector,

3. Press down on the release tab,

4. Pull the connector straight off,

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 fuel sending unit, 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. Refer to diagram at the

beginning of Step 2

D. With the fuel tank empty of fuel, unbolt the tank straps and remove it

from the vehicle.

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

fuel tank. This is spring loaded, so, holding it down while removing

the ring will prevent the sending unit from popping up and possi­bly causing damage.

F. Note the location of the tab and arrow. Re-install the sending unit in

the same location to prevent the fuel level arm from binding.

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

fuel tank without bending fuel level arm.

H. Place the tank on blocks to simulate the tank hanging. Failure to do

this step may result in the draw tube being cut too short.

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

I. Assemble the BHF-1002 with a PL-1004 in ‘S’ using thread tape. In-

sert 1/2” brass plug into the ‘R’ port. Torque both to 40 lb./ft.² Push
the ST-1005P onto the barbed portion of the BHF-1002. Insert O-ring
into groove.

J. Place the lock ring back on the tank and locate the BHF-1002 bulkhead fitting on the tank with enough

clearance for the fuel line and fittings. Keep in mind the bulkhead must also clear the bottom of the
bed support structure. The fiberglass protective shell will have to be trimmed as necessary for clear­ance.

K. Once location has been established, double check! Make sure the fuel line and fittings will clear

the trimmed protective shell. Mark location and drill 1 1/2” hole with hole saw. Hold a cup or catch
can inside the tank while drilling to catch any debris. Place a rag over the opening to prevent tank con­tamination. Double check for debris around the ring and inside tank.

L. De-burr hole and check for fit.

M. 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. Measure twice and cut
once! Using a razor knife, cut to proper length. If unsure of correct
length, make small cuts until proper length is achieved.

N. Install Bulkhead with lock washer and nut. Tighten nut securely with a

1-7/8” socket or wrench. Make sure the fittings are unobstructed.

O. 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. Loop fuel
line over frame. Do not cut at this time. Reinstall fuel tank making sure to reconnect factory suction,
return, electrical connections, and filler neck tubes. 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.

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

A. Route suction line from the suction tube assembly to the ’T’ port on

the FASS pump. Cut the fuel line and insert PL-1005 using oil. At­tach to 10-300 in ‘T’ port. Torque to 18 lb./ft.²

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. Insert PL-1005 into fuel line using oil. Attach to 10-300 located in

the port labeled ‘E’.. Torque to 18 lb./ft.² Route this line to the en­gine side of the factory lift pump.

D. Disconnect factory power to the lift pump. Drain fuel from factory

lift pump.

E. Disconnect the yellow-clipped factory feed at the factory lift pump.

Refer to diagram at the beginning of Step 2.

F. Using oil, insert PLB-1212 into one end of FL-1002 fuel line. Oil the PLB and slide into the yellow-

clipped factory feed fitting until you hear a click. Push down the locking tab.

G. Disconnect both factory return lines from the factory lift pump (Refer to diagram at the beginning of

Step 2). Insert DB-4646 into each return line fitting until you hear a click and tabs lock.

H. Clean and cap off the factory return ports with the two RVC-38 caps. Clean and cap off the factory

feed port with the RVC-12 cap. Seal factory electrical connection with di-electric grease or similar to
prevent corrosion.

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 55 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.

 Recheck all fluid and filter connections for leaks (with engine running).

 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 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