DRIVEN DIESEL DD-60FS-FBD-UPGRADE-V2 Fuel Bowl Delete Upgrade Kit Installation Guide
- June 4, 2024
- DRIVEN DIESEL
Table of Contents
FUEL BOWL DELETE UPGRADE KIT FOR
STANDARD REGULATED RETURN SYSTEM
Fits 03-07 6.0L Powerstroke Diesel – Single or Dual Alternator
Installation Guide
DD-60FS-FBD-UPGRADE-V2 Fuel Bowl Delete Upgrade Kit
INSPECT THE CONTENTS OF THIS KIT THOROUGHLY BEFORE STARTING THE INSTALLATION
PROCESS!
IF YOU FIND A PROBLEM WITH YOUR PACKAGE:
- KEEP ALL OF THE PARTS & PACKAGING TOGETHER
- DO NOT ATTEMPT INSTALLATION OF THE PRODUCT
- PROMPTLY NOTIFY YOUR SELLING DEALER
- PROVIDE DEALER WITH PHOTOGRAPHS IF REQ’D*
- WAIT FOR FURTHER INSTRUCTIONS FROM THE DEALER
*WE RESERVE THE RIGHT TO REQUEST PHOTOGRAPHS OF PACKAGING OR PARTS IN ORDER TO PROPERLY ADDRESS ANY SITUATION INVOLVING EITHER DAMAGED OR MISSING ITEMS.
THANK YOU FOR YOUR COOPERATION!
hank You for purchasing the Driven Diesel FUEL BOWL DELETE UPGRADE KIT for
your current Standard Regulated Return fuel system! Please read and
familiarize yourself with this manual fully before proceeding with the
installation of the kit. Also, always work safely. Make sure that there is
plenty of light and adequate ventilation, and allow yourself several hours to
complete the installation. After reading these instructions, if you feel that
the installation is beyond your capability, please have this kit installed by
a qualified mechanic.
Finally, the installation of this kit requires exposing the fuel system.
Diesel fuel is flammable, and its vapor is explosive; therefore common sense
dictates that there be no smoking or open flame within 50 feet of the
workspace. If any fuel spills, contain it and wipe it up immediately. Do not
let the fuel stand on any painted surfaces of your vehicle, or damage to the
finish may occur. We HIGHLY RECOMMEND having an appropriate fire extinguisher
close by!
Please don’t hesitate to contact Driven Diesel should you have any questions.
Contents of Driven Diesel 6.0L Fuel Bowl Delete UPGRADE KIT
Please use the following parts list and pictures to become familiar with this
kit. All of the parts listed below should be contained in your kit. Please
notify us if you are missing any parts BEFORE starting your installation! We
will refer to the different fittings by their part number throughout the
installation.
| Qty: | Part Number: | Description: |
|---|
1
1
1
1
2
1
1
2
1
1
3
1| 60FS-FBDDSF-TUBE-V2 60FS-FBD-RTN-HOSE 60FS-FBD-ASSY
QD-5/16×8-SS
12-washer
M8 x 80mm Stud
M8 x 140mm Stud
3/4×3/4 Spacer
3/4×5/16 Spacer
3/4×5/32 Spacer
1/4″ Flat Washer
M8 Nylok| Driver Side Feed Tube Assembly – Fuel Bowl Delete Specific
Regulator Return Hose Assembly – Fuel Bowl Delete Specific
Custom Machined Fuel Bowl Delete and Bracket Assembly
Fuel Pump Delete Tube (bypasses OEM fuel pump return circuit)
12mm Copper Banjo Bolt Washers
8mm x 80mm Stud
8mm x 140mm Stud
3/4″ Diameter x 3/4″ Tall Aluminum Spacer
3/4” Diameter x 5/16” Tall Aluminum Spacer
3/4” Diameter x 5/32” Tall Aluminum Spacer
1/4” Flat Washers
M8 Nylok Nut
IMPORTANT NOTE ABOUT DELETING THE FILTER BOWL:
Due to the fact that the fuel filter bowl and the oil filter bowl are
integrated units, you have a few different options for deleting the fuel
filter bowl. You need to be aware of these options and make sure you are
prepared for whichever you choose BEFORE you begin the installation of this
kit. Your options are:
A. Retain YOUR Factory Oil Filter Bowl – in order to do this, you will need to
remove the stock oil/fuel filter assembly, cut the fuel filter bowl off of the
oil filter bowl and clean up the cut area of the oil filter bowl with a
grinder or similar. Then thoroughly clean the oil filter bowl and reinstall it
with a new filter and O-ring.
B. Install a replacement oil filter bowl that does not require modification.
We offer this part as an option when ordering this kit. Simply remove your old
filter bowl assembly and install the replacement oil filter bowl with a new
oil filter & o-ring.
C. Run a remote oil filter assembly (like those found in a Bullet Proof Diesel
oil cooler kit, or similar). In this instance, you will not have any oil
filter bowl in the engine valley. NOTE: SHOULD BE INSTALLED BEFORE OR DURING
INSTALLATION OF THIS FUEL BOWL DELETE THE FUEL SYSTEM KIT!
Some of the Basic Tools Needed for Installation:
Standard Combination Wrench Set
3/8” Drive Metric Socket Set
T-27, T-30, and T-45 Torx Wrenches| Metric Combination Wrench Set
1/4” Drive Metric Socket Set
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Let The Fun Begin!
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Begin by disconnecting both batteries (negative cables first, then positive). TIP: Write down your radio stations first.
-
Remove the entire airbox/intake system.
-
Remove both driver-side intercooler tubes.
-
Remove fuel from the filter bowl by either removing the cap and sucking it out with a shop syringe or removing the test port plug and draining it into a cup or rag.
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Disconnect the driver-side fuel line from the 90° fitting on the rear of the fuel filter bowl.
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Remove the driver-side front banjo bolt, washers, and finally the driver-side fuel line.
-
Disconnect fuel Supply and Return lines from filter bowl using a 13/16” wrench. These lines will NOT be re-used. We recommend disconnecting the flexible fuel line quick disconnect fittings (using a fuel line release tool) from the other end, removing the bolt from the retaining bracket on the front of the head, and completely removing the metal lines from the engine. See the image at the top of page 6 for clarification.
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Disconnect the passenger side fuel feed line from the 90° fitting on the front of the fuel filter bowl. This line will be reused in a later step so just let it lay there for now.
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Disconnect the return hose from the bottom of the fuel pressure regulator and from the side of the billet fitting that is mounted to the fuel filter bowl. This hose will NOT be reused.
IF YOU ARE RUNNING A BULLETPROOF DIESEL OIL COOLER KIT OR ANY OTHER SIMILAR KIT THAT NO LONGER USES THE STOCK OIL FILTER ON THE ENGINE: REMOVE THE STOCK OIL FILTER HOUSING IF IT IS STILL INSTALLED. IT IS NO LONGER NEEDED AS THE MOUNTING POINT FOR THE STOCK FUEL FILTER BOWL. SIMPLY REMOVE THE (4) T-45 TORX BOLTS FROM THE BASE OF THE OIL FILTER HOUSING AND REMOVE THE HOUSING FROM THE TRUCK AT THIS TIME. SKIP FORWARD TO STEP 18 -
Remove the oil filter cap and oil filter. This will allow the oil in the oil filter bowl to drain back into the oil pan.
-
Take note of the wiring harness that passes between the fuel and oil filter bowls. In some years it is below the bridge that connects the two filter bowls, in others it is above the bridge. If the harness is ABOVE the bridge, you will need to remove the standpipe from the oil filter housing before proceeding. If the harness is below the bridge, skip ahead to step 18.
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Locate the T-30 Torx bolt that retains the black plastic standpipe in the bottom of the oil filter housing and remove it. Once the bolt is removed, rotate the standpipe counterclockwise to release it and lift it out of the filter bowl. Set the standpipe aside as you will need to reinstall it in a later step.
-
Once the oil filter bowl has drained, remove the (4) T-45 Torx bolts at the base of the oil filter bowl. At this point, you should be able to remove the oil/fuel filter bowl assembly from the truck. If your wiring harness is routed above the bridge, you may have to twist and turn the bowl assembly to get it out from under the harness.
-
If you are going to modify and keep your current oil filter bowl, now is the time to do so. We recommend cutting the fuel filter off as close to the oil filter bowl as possible (leaving the least amount of the “bridge” sticking out of the oil filter bowl when done) and then using a grinder to eliminate any sharp edges. Once you have made your modifications to the bowl, THOROUGHLY wash and dry it to prevent any debris or contamination from entering your engine after reassembly.
-
If removed, reinstall the oil filter standpipe and its T-30 retention bolt. Torque the bolt to 27in/lbs (yes…INCH pounds!).
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If you are using a new oil filter bowl & o-ring, remove and discard the old o-ring that sealed the base of the oil filter bowl to the top of the oil cooler cover and install the new o-ring in its place.
-
Set your oil filter bowl in place and loosely start (3) of the original T-45 Torx bolts. Tighten these bolts each a little at a time until snug. Torque the (3) T-45 Torx bolts to 11ft/lb.
-
Depending on your setup, you will use either the LONG (140mm) or the SHORT (80mm) stud for this step. If you are using a STOCK-FORD OIL COOLER, you need the LONG stud. If you are using a BULLETPROOF DIESEL REMOTE OIL COOLER, you need the SHORT stud. Locate the oil filter bowl mounting hole that is farthest forward on the driver’s side. It’s right against the bend of the intake manifold. Thread the stud “finger tight” into this hole.
-
Install the aluminum spacers over the previously installed stud. This will be the starting point for positioning the fuel bowl delete bracket. See the yellow box below Step 22 for notes about adjusting spacer height for your specific engine.
a. OEM OIL COOLER: Use (1) of each size aluminum spacer (you will have one tall spacer left over).
b. BULLETPROOF DIESEL OIL COOLER KIT: Use ALL (4) aluminum spacers. -
Set the Driven Diesel Fuel Bowl Delete block with the attached bracket over the stud. The rear fitting should be pointing toward the driver’s side and slightly down, and the front fitting should be pointing toward the passenger side and slightly up. The jamb nuts on both fittings should still be loose so the 90° fittings can be rotated as needed.
-
Locate the 60FS-FBDDSF-TUBE, along with a Banjo Bolt and (2) Copper Washers. Even though it is not shown in the pictures, leave the rubber bumper installed on the tube. Drop the banjo end of the 60FS-FBDDSF-TUBE down behind the thermostat housing. Once it comes out below the thermostat housing, you can hold it from the top and position it to easily insert a banjo bolt with a copper washer installed through the banjo end of the tube. Install 2 copper washers on the banjo bolt, so there is one on each side of the banjo fitting on the tube. Then carefully rotate the tube into position on the front of the head and loosely start the banjo bolt into the threaded port. Install the bolt hand tight for now, the tube should still move a little until we get it connected to the bowl delete fitting.
-
Due to variances in castings, cylinder head machining, or other aftermarket part usage, the next step may require a little bit of adjustment to get things aligned properly. Alignment adjustments will be made by rotating the rear 90° fitting on the bowl delete block and/or changing the spacers under the mounting bracket. If the bracket needs to go up more, add 1 washer at a time on top of the spacers (but under the bracket). If the bracket needs to go down, remove the small aluminum spacer, replace it with 2 washers and check again. Remove 1 washer at a time to further adjust. The ultimate goal is to get the tube and the 90° fitting aligned so that they are in a straight line and the tube nut starts easily. When properly aligned, the bracket should be sitting flat on the spacers such that tightening the nut doesn’t put any significant stress on the assembly. See the images below for further clarification.
NOTE: Due to recent changes to accommodate the ODawg S2
intake manifolds, the bowl delete bracket, and the block will sit higher above
the intake manifold than pictured here. -
Once you get the tube nut at the top of the 60FS-FBDDSF-TUBE started, tighten it Hand Tight. At this point, the tube should be properly aligned
-
Tighten the banjo bolt to 20ft/lbs MAX (1/16-1/8 turn past “finger tight”!) If you do not have an accurate, short-handled, small drive torque wrench for this, please just tighten with a wrench to the point that it stops, then just a “bump” tighter to seal the washers.
-
Tighten the tube nut at the top of the 60FS-FBDDSF-TUBE. It’s a good idea to use a second wrench on the 90° fitting so the bracket and/or tube don’t get bent. You can also tighten the locknut on the 90° fitting in the rear port of the fuel bowl delete block.
-
Tighten the nylon nut that retains the fuel bowl delete bracket to the stud.
-
Connect the 45° fitting of the existing 60FS-PSF-HOSE to the front fitting of the fuel bowl delete block. You may need to adjust the angle of the fitting in the fuel bowl delete block so that the 45° hose end is pointing slightly downward. You may also need to loosen the other end of the existing 60FS-PSF-HOSE and rotate the entire hose to get it to align perfectly with the new fitting.
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Tighten the locknut on the 90° fitting (you’ll need to hold the fitting with one wrench while tightening the locknut with another). See the TOP RIGHT image above for orientation.
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Tighten the 45° hose end to the 90° fitting.
-
If applicable, re-tighten the straight hose end that you loosened to reposition the hose.
-
Locate the 60FS-FBD-RTN-HOSE. The 45° hose end is connected to the fitting on the bottom of the fuel pressure regulator. The hose should be run down the front of the cylinder head, in the same location that the factory steel fuel supply and return lines were found.
-
The Quick-Disconnect tube end of the Driven Diesel return line is connected to the factory return hose, which is shaded in BLUE in the image at the top of the next page. It is helpful to put a little lubricant on the end of the Driven Diesel quick disconnect tube end, so that it slides nicely into the internal o-rings of the quick disconnect fitting.
-
Locate the QD-5/16×8-SS tube (straight tube with 2 male quick disconnects). This tube is installed between the RETURN (smaller) hoses that connect to the OEM fuel pump. Remove the OEM fuel pump and replace it with this tube. OEM Supply hoses will remain disconnected.
IMPORTANT NOTE: When installing the return hose, make sure that the Quick Disconnect locks into place and can’t be pulled out of the factory hose without using the release tool.
FUEL SUPPLY CONNECTION
The Driven Diesel Fuel Bowl Delete Regulated Return Fuel System was NOT designed to be used with the stock Ford fuel pump. Due to the fact that there are a number of different fuel supply systems that can be used with this Regulated Return, we cannot provide specific instructions for every possible configuration. The information below is provided to help you locate whatever parts are necessary to connect your chosen fuel supply system to our Fuel Bowl Delete Regulated Return Kit.
The Fuel Inlet Port on top of the Driven Diesel Fuel Bowl Delete Block is a STANDARD #6 MALE AN type fitting. If you are using a Driven Diesel Race Fuel Supply System, this will match up perfectly with the hose and fittings we supply in that kit. If you are using another type of fuel pump or delivery system, you may need to adapt your setup. We recommend using a 90° #6 AN hose end to connect to the fuel bowl delete inlet fitting. It is generally easiest to use all #6 hose and fittings from the outlet of your Post-Pump fuel filter all the way up to the inlet of the Fuel Bowl Delete. -
Locate the supplied fuel pressure gauge. This gauge has pipe thread, so a sealant like Teflon tape is required. Apply your chosen sealant to the threads and install the gauge into the port on the front of the fuel pressure regulator and tighten.
YOU’RE ALMOST DONE!
Before proceeding, it’s time to DOUBLE CHECK EVERY fitting and bolt for proper tightness.
Carefully go over each of the fuel lines that were touched for this upgrade, checking both the line and the fittings for tightness. Once you’ve verified all of the fuel lines and fittings, check any bolts that have been removed and reinstalled up to this point. Once reassembly is complete, some of these fittings and hoses will not be easily accessible should you miss one and leave it loose! -
Now we need to check for leaks. Start by turning the key to the “on” position (do not crank or start the engine) and let the fuel pump run until it shuts off. When the fuel pump shuts off, turn the key to the “off” position. You will need to temporarily reconnect the battery cables for this.
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Repeat the above 8-10 times to refill fuel lines and rails and purge them of air.
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Now, cycle the key to the “on” position and your fuel pressure is still 65psi. Adjust if necessary, but you shouldn’t need to because we didn’t touch the regulator adjustment.
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Cycle the key to the “on” position and re-check the new parts for leaks. The system is under pressure now so they should be pretty apparent…take your time, this is important!
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If any leaks are found, resolve them before proceeding. It’s much easier to address them now than when everything is back together later.
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Reinstall the intercooler tube, intake, and battery cables.
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Start the engine and allow it to idle. While it’s idling, thoroughly inspect for leaks one more time as everything is once again under pressure and flowing constantly. Any remaining air in the system will also be purged during this time.
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If any leaks are detected, shut the truck off and resolve them before proceeding. Come back and perform another leak check and proceed once the problem has been resolved.
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Once the system is leak free and the truck has had a few minutes to purge any remaining air and start to build some engine heat, adjust the fuel pressure and tighten the fuel pressure lock nut. We recommend starting with the pressure set to 65psi at operating temperature.
CONGRATULATIONS! You’ve just completed Fuel Bowl Delete Upgrade to your
Driven Diesel 6.0L Regulated Return Fuel System Kit! Please Note: It is
recommended that fuel filter service intervals be kept to no less than every
15k miles (or 1x per year…whichever is first), regardless of the filtering
setup you are running.
Common Fuel System Issues – Troubleshooting Guide
If you run into any problems after the installation of your fuel system,
please check this page for guidance before calling your dealer or Driven
Diesel for help. The issues below represent the most common causes of
technical support calls.
-
THE REGULATOR MUST BE BROKEN – PRESSURE IS LOWER THAN DESIRED – This is a multi-part problem, but the first thing you need to know is that if you don’t have fuel spraying out of the hose connected to the brass nipple in the top half of the regulator, the regulator is NOT broken and is working fine. The fuel pressure regulator supplied with our kits is extremely simple, and the ONLY failure we have ever seen, since we started building fuel systems in 2001, has been a punctured diaphragm…which will leak fuel from the brass nipple. See below for some specific examples of where to look for your fuel pressure problem:
a. AIRDOG II – If you have an AirDog II/4G/5G pump that has replaced your factory fuel pump, you will need to adjust the fuel pressure at the pump. The ADII pumps are delivered from the manufacturer with the internal regulator set at 55psi. Locate the adjuster screw/jamb nut. It is best to adjust the DRIVEN DIESEL fuel pressure regulator up (clockwise) several turns past the max pressure than have someone adjust the ADII pressure adjuster until the DRIVEN DIESEL gauge shows about 80psi. Finally, adjust the DRIVEN DIESEL regulator down to 60-65psi. This will leave you with about 5-10psi of “overhead” pressure, which will help keep the pressure at the desired level when you are heavy on the throttle and the injectors are using more fuel from the rails.
b. FASS – If you have a high-pressure FASS pump and are unable to get 65psi at the Driven Diesel fuel pressure regulator, you may need to update the regulator in your FASS pump. Older Grey or Black High-Pressure FASS pumps were delivered with a 55psi regulator spring. Newer Black FASS pumps (Serial Number S399570 OR HIGHER) have a 65psi regulator spring. All of them can benefit from our 75psi regulator upgrade, to ensure that you are able to get the proper 65psi at the engine, with pressure overhead for high-demand situations. See our website for help determining which upgrade you need. -
FUEL LEAKING FROM BRASS NIPPLE OR RUBBER TUBING UNDER TRUCK – The brass nipple in the top half of the fuel pressure regulator is a “boost reference port”. This is used to increase fuel pressure as the boost increases…IN GASOLINE APPLICATIONS! We do NOT use this port in diesel applications because it poses a serious risk of a “runaway” situation should the diaphragm in the regulator fail. Instead, we run a long piece of poly tubing from this port to a location under the truck, to make sure that fuel is not sprayed all over the engine in the event of a diaphragm puncture. In the event of a punctured diaphragm, contact us at 623-582-4404 to purchase a replacement.
S DIESEL, LLC (dba STRICTLY DIESEL AND/OR DRIVEN DIESEL) WARRANTY, AND
LIABILITY POLICY
MOST OF THE PRODUCTS SOLD BY S DIESEL, LLC, ARE DESIGNED TO INCREASE VEHICLE
PERFORMANCE…USE
AT YOUR OWN RISK!
Do not install or use any product(s) purchased from S DIESEL, LLC (“S DIESEL”)
until you have carefully read the following Warranty and Liability Policy (the
“Warranty”).
PRODUCT WARRANTY POLICY
Subject to the limitations, exclusions, and qualifications set forth below,
the product or the products made and sold by S DIESEL (the “S Diesel Product”
or “S Diesel Products”) are warranted to the Buyer as set forth in this
Warranty. The installation of the S Diesel Products indicates that the Buyer
has read, understands, and agrees to the terms and conditions of this
Warranty. Any warranty on products that are made by another manufacturer which
are resold by S DIESEL to Buyer is made to Buyer by the manufacturer of such
products in accordance with and subject to all conditions and limitations of
the manufacturer’s warranty in effect on the date of the purchase by Buyer. S
DIESEL makes no warranties to Buyer, express or implied, with respect to such
products that are made by another manufacturer.
LIMITED WARRANTY
The S Diesel Products (except S Diesel Products specified to have different
warranty terms) are warranted to be free from defects in material and
workmanship, under normal use and service for a period (the “Product Warranty
Period”) of one (1) year from date of delivery to Buyer, unless S DIESEL
performs the work installing the S Diesel Products, in which case the Product
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defined below under “SERVICE WARRANTY POLICY”). S DIESEL’s liability under
this Warranty is limited to repair or replacement at its option, subject to
the provisions set forth herein, of any S Diesel Products which upon
examination S DIESEL are found to be defective. Buyer shall prepay the cost of
transportation of defective S Diesel Products to S DIESEL for inspection.
S DIESEL shall not have any responsibility under this Warranty unless (1) the
defect in an S Diesel Product results in a claim arising within the Product
Warranty Period, measured from the date of delivery to Buyer, (2) the S Diesel
Product if installed by an installer other than S DIESEL, was properly
installed, (3) the S Diesel Product was normally maintained and not subject to
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components and/or accessories were not repaired or altered in such a way that
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DIESEL.
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Limited Warranty above shall be Buyer’s exclusive remedy for and shall
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AND RESELLABLE CONDITION, BE RECEIVED WITHIN FIFTEEN (15) DAYS OF THE ORIGINAL
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THE BUYER HAS READ, UNDERSTANDS, AND AGREES TO THE TERMS AND CONDITIONS OF
THIS WARRANTY.
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This Warranty is for the exclusive benefit of the Buyer and is not assignable.
WARRANTY CLAIMS PROCEDURE
Warranty claim forms can be printed from the company websites (
http://www.drivendiesel.com (Products) and
http://www.strictlydiesel.com (Services)). A properly completed warranty
claim form and a copy of the invoice for any defective Product or Service must
be received by the Seller within the earlier 30 days after the expiration of
the Warranty Period or the incident giving rise to the claim. To qualify for
an adjustment under this Warranty a defective Product must be returned prepaid
to the Seller for inspection and must be accompanied by a dated proof of
purchase receipt. In addition, the serial number of the defective Product, if
any, must match the serial number on the Buyer’s invoice. All Warranty claims
are subject to approval by the Seller and/or the Product’s manufacturer. The
buyer must pay all applicable service charges and taxes. Defective Products
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purchase receipt.
WAIVER
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Warranty Provisions shall in no way constitute a waiver of such right. No
claim or rights arising out of a breach of the Warranty Provisions by Buyer
may be discharged in whole or in part by a waiver of the claim or right unless
the waiver is in writing and signed by an authorized representative of S
Diesel. S Diesel’s waiver or acceptance of any breach by Buyer of any
provisions of the Warranty Provisions shall not constitute a waiver of or an
excuse for nonperformance as to any other provision of the Warranty Provisions
nor as to any prior or subsequent breach of the same provision.
APPLICABLE LAW
The Warranty shall be governed by the laws of the State of Arizona (excluding
Arizona law with respect to conflicts of law).
DD-60FS-FBD-UPGRADE-V3
Last Updated: 8/24/2022
© Driven Diesel, LLC