FASS Titanium Series Diesel Fuel Lift Pump Instruction Manual

TITANIUM SERIES
INSTALLATION MANUAL
ALL 1/2” FUEL PORTS

FASS DIESEL FUEL SYSTEMS® / ENGINEERED EXCELLENCE
www.fassride.com
(866) 769.3747

Titanium Series Diesel Fuel Lift Pump

APPLICATION:
TS-C10-100G
(100GPH @ 8-10PSI)
TS-C10-165G
(165GPH @ 8-10PSI)

DURAMAX 2500 & 3500
Standard Pickup Truck 2001-2010
*NOTE: CAB AND CHASSIS MAY REQUIRE MODIFICATIONS

Thank you for cho osing FASS, from Diesel Performance Products, Inc.
FASS specializes in building extremely high-quality fuel products. We have earned an unsurpassed reputation for excellence in our industry by using only the highest-quality American-made components. In order to support our American workers and our  American economy, more than 98+ percent of our products are manufactured completely in the United States.
Of course, that dedication to excellence comes at a price, but it is important to remember that price does not dictate quality-quality dictates price! We will never compromise by using cheaper, foreign-made components, like so many of our competitors do.
Customer satisfaction is our top priority and we strive always to provide outstanding customer service. Our Research and Development department, in conjunction with our Dealer Support Department, continually searches for ways to improve quality, expand  our product line, and provide superb support. Our exclusive ViP Network ensures that customers receive the proper products and support at the local level. The extended lifetime warranty is only available on products purchased from the network. There is no  warranty on products not purchased outside the network.

IMPORTANT:
In order to qualify for the lifetime extended warranty, your product registration form and proof of purchase from an authorized dealer must be submitted to FASS Fuel Systems within 30 days of purchase. Failure to comply will void the warranty. We have the  right to deny any warranty believed to be false, altered or purchased through an unauthorized or terminated dealer. A current list of authorized dealers can be found on our website, FASSRide.com.
The complete conditions of the Limitation of Warranty can be found in the back of this manual, and FASSRide.com.

For more information, contact Technical Support:
Diesel Performance Products, Inc.
16240 State Hwy O. Suite B
Marthasville, MO 63357
636-433-5410

WARNING!
This product has NO WARRANTY unless:
1. It has been purchased from an Authorized or ViP FASS Dealer. If in doubt, check www.FASSRide.com. (If your purchase was made on Amazon.com, the warranty is void. Return the FASS product to the seller and get a refund).
2. It is registered within thirty (30) days of purchase.
Other conditions may apply. Please see full warranty information.

ATTENTION!
Before you begin installation
Register for your Warranty ONLINE at https://www.fassride.com/register- awarranty/
No online access, call our TECH Support at 1-866-769-3747

FOLLOW THESE STEPS TO ENSURE A SIMPLE, CORRECT INSTALLATION OF YOUR NEW TITANIUM FUEL SYSTEM

ATTENTION:
Be sure to identify the proper FASS System and fuel line  configuration. For help, our product finder can be found at www.FASSride.com. Follow the instructions to see fuel line detail.

1. Be sure the serial number on this installation manual matches that on the outside of the box.

2. Pay close attention to ALL WARNINGS

3. Read all instructions before starting installation of this product.

4. Inventory the package components. Notify the place of purchase immediately of any parts missing or damaged.

5. The installation recommendations contained herein are guidelines. Use good judgment and take into consideration your vehicles’ accessories.

6. 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 or problem arises during the installation, the dealer is prepared to handle it. Diesel Performance Products, Inc. is not responsible for any installation mistakes.

7. If you have any questions or concerns that cannot be addressed with your dealer, email or call FASS.

If any installation procedure is uncertain, contact FASS technical support.
Call customer service at 636-433-5410, or send us an e-mail: [email protected] with the following information:

Your name, address and daytime phone number
Model (TS-C10-100G) or (TS-C10-165G)
Serial Number
Last 6 digits of vehicles’ VIN

INSTALLATION MANUAL
TS-C10-100G or TS-C10-165G
(Installation Videos are available at www.fassride.com)

Recommended Application
T S- C10-100G: Duramax 2001-2010 with stock – 600 horsepower modifications
T S-C10-165G: Duramax 2001-2010 with 600 – 1,000 horsepower modifications

1. Read all instructions before starting installation of this product!

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

3. Secure vehicle from ROLLING!

4. Cab and Chassis may require modifications

5. Consult vehicle’s manufacturers’ instructions concerning the electrical system before at-tempting any electrical connections.

6. Be sure that the serial # on this installation manual matches that of the outside of the box.

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

8. Keep debris from entering the internals of the system during installation. Getting debris in the water separator nipple can lock up the motor. If the motor does lock up from debris call FASS for technical assistance.

9. Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel.

10. Properly secure lines to prevent chaffing.

BEFORE STARTING THE INSTALLATION PROCESS LUBRICATE THE BED BOLT WITH WD-40 TO HELP WITH INSTALLATION

WARNING!
Always be sure to fill the fuel tank to full after a new FASS installation. Failure to do so can result in excessive sound output, or priming issues!

TITANIUM SIGNATURE SERIES
100 GPH or 165 GPH
8-10 8-10 psi (Ap psi (Ap proximately) proximately)

PUMP GGUIDE:

1. “E” To Engine
2. “R” Return to Tank
3. “H” Coolant Heater Ports
4. Serial Number
5. “T” Fuel Inlet
6. Electric Heater Ports
7. “6” Gauge Port

TITANIUM SIGNATURE SERIES
100 GPH or 165 GPH 8-10 PSI (Ap proximately)
Note: Going over 30 PSI WILL void warranty.

NOTE: WARRANTY MAY BE VOID IF SILICONE BAND IS REMOVED FROM MOTOR!!
The silicone band is in place to retain motor wires, preventing damage to the electric motor.

CONTENTS

NOTE: Owner’s Manual available for download on our website, www.FASSride.com

MOUNTING PACKAGE CONTENTS

STEP 1: INSTALL ELECTRICAL HARNESS

The installation of the electrical harness is done first, allowing power to be applied to the pump for lubrication purposes later in the installation.

NOTE: USE SUPPLIED DIELECTRIC GREASE SPARINGLY ON ALL ELECTRICAL CONNECTIONS! BE SURE TO GREASE RELAY PIGTAIL!

Install the Relay Cover onto the relay on the FASS harness.

NOTE: BE SURE TO INSTALL THE SUPPLIED 10 AMP FUSE INTO THE FASS WIRING HARNESS!!

The installation of the electrical harness should be completed first. This will allow power to be applied to the pump during installation.

A. Using wire stripping tool remove excess insulation off the add-a-fuse and the WH-1006-3

B. Place wire from 46044 and single red bare wire from WH-1006-3 into butt connector. Using crimping tool connect 46044 and WH-1006-3 with butt connector. Install 46260 to 46044 top slot (opening that is near the spade).

C. Crimp the ring terminals to the red and green wires of the WH-1006-3 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 preventative on electrical connections is  recommended.

D. Secure relay and fuse in an upright position, as shown, to prevent moisture from entering. Dielectric grease may be applied to prevent corrosion.

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-1006-3 wire harness along frame rail to mounting location of pump. Completion of this step will be addressed in the Mounting Step 3.

STEP 2: PREPARE SUCTION & RETURN LINES

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

A. Remove the 3 bolts holding the factory Return Fuel cooler to the mounting bracket. The fuel cooler is located in front of the fuel tank.

B. 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.

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

C. Using oil, insert PLB-1212 into one end of the provided FL-1002 fuel line. Feed line over frame to the stock fuel connection.

D. Push the PLB-1212 into the factory suction line until you hear a click and the tabs are locked in place.

E. Using an HC-1001 hose clamp, insert the A614C56-55-05 into the other end of the provided FL-1002 fuel line and secure. Loop this end over the frame to the factory steel fuel line disconnected in Step 2b. Oil the rings inside the A614C56-55-05 and slide over  the line until you hear a click. Press the locking tab of A614C56-55-05. Do not cut the line at this time.

F. Some filler necks have the integrated over-flow tube. If your filler neck does not have a separate over-flow tube, you have an integrated filler neck. Mark location for the Return manifold on the rubber over-flow tube. Loosen the clamps on both ends of the filler  neck and remove screws from fuel receptacle. Remove filler neck assembly. Slide rubber outer hose down exposing filler tube. At mark, cut hose. Make sure there is enough tube on each side of the cut to insert the RM-1001 and to place the hose clamps.  Slide top half over filler tube with HC-1003 clamp. Slide RM-1001 Return Manifold over the filler tube and into over-flow hose with the small junction pipe pointing toward the fend-er. Slide another HC-1003 clamp and bottom hose over filler tube and secure.  Re-install filler neck assembly.

Prepare FASS return line by cutting rubber junction connecting the two halves of the filler neck.
Position RM-1001 with the 1/2” junction pipe aiming to outside of bed. Clamp rubber and RM-1001 using both HC-1003’s.

G. Position RM-1001 with the junction pipe aiming to outside of bed. Connect rubber and RM-1001using both HC-1003’s.

NOTE:
ATTENTION: While installing fittings into Titanium pump
DO NOT Apply side pressure to draw tube of pump p

STEP 3: MOUNT FUEL SYSTEM

NOTE: Before installing fittings make sure to inspect for burs or flare imperfections. When cutting fuel line make sure to blow out line to keep debris from moving forward..

A. Install 10-300 into the “E” port and 10-301 into the “T” port of the FASS, torque to 18 ft./lbs.
FITTINGS COME EQUIPPED WITH THREAD SEALANT, DO NOT USE THREAD TAPE

B. For fitting purposes. Secure PBR-2001 to pump assembly lightly with (3) 1/4”-20×1 3/4 bolts and (3) WA-1001D. Assembly will be used in future steps for correct fitting of brackets. (Note: Bracket may-be flipped to accommodate your application.)

C. Connect female plug of the FASS harness into pump. Turn key to “on”. With pump operating (you may have to bump the starter), turn pump over, liberally spray WD-40 (or equivalent) into water separator nipple lubricating Gerotor.

D. Unbolt driver side front bed bolt from bed retain bolt for future use. Align RS-2001 with PFB-2002.

E. Secure PFB-2002 and RS-2001 with bed bolt in previous step.

F. Position the PBR-2001 to the PFB-2002 pump assembly at the mounting location and check for fit. Once location is established mark location for mounting in next step.

G. Assemble the FASS pump bracket PBR-2001 using the RS-2002 spacer between PFB-2002 and PBR-2001 bracket with 4-3/8 bolts, nuts, and washers. Note: Torque bolts not flange nut.

H. Once secure use 3-1 1/2 bolts and 3-WA-1001D spacers to mount the pump to the bracket.

I. Apply motor oil to gasket located on filters. Attach to system and hand tighten.

STEP 4: INSTALL FUEL LINE

Caution: DO NOT use sealant on AN fittings

A. Route suction line from the factory suction (PLB-1212) to the ‘T’ port of the FASS pump. Cut FL-1002 to length. (measure twice cut once) Insert PL-1005 using oil. Attach to 10-301. Torque to 18 ft./lbs.

B. Measure from the factory feed connection from Step 2d to the ‘E’ port of the FASS system. Cut and insert PL-1005. Connect to the 10-300 in the ‘E’ port of the FASS system. Torque to 18 ft./lbs.

C. Using oil, insert a PL-1005 into the remaining fuel line. Connect to the ‘R’ port fitting on the FASS  system. Torque to 18 ft./lbs. Route this line in a gentle bend to the Return Manifold. Slide over return tube and secure with HC-1001 clamp.

D. Reattach the 3 bolts holding the fuel cooler to the mounting bracket.

Note: Secure all fuel lines with cable ties. Cable ties are an economical way to prevent the possibility of problems occurring!

STEP 5: REVIEW INSTALLATION

1. Blow out any open lines/cover any open ports

2. Bolts and fasteners properly tightened?

3. Electrical harness and fuel lines secured and properly tightened? Reconnect the battery.

4. Has the system been primed?
   a. Turn key to the ignition position, turning on the FASS pump for 15 sec..
   b. Crank engine and allow to run for at least 1 minute.

5. Check for leaks.

6. Start the engine

7. Recheck all fluid and filter connections for leaks

8. 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
   To assist with priming your FASS pump crack the XWS-3002. Put power to the FASS pump to activate the pump. When the tone of the pump changes you can tighten up the fuel filter. If you need a video of the priming process go to www.FASSride.com.

LIMITATION OF LIFETIME WARRANTY

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. Warranty is voided if used with other than diesel fuel. 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.
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 nongenuine 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 UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.

®FASS Diesel Fuel Systems is a Registered
Trademark of Diesel Performance Products, Inc.
© Copyright 2016, Diesel Performance Products, Inc.

References

• Amazon.com
• FASS Diesel Fuel Systems - Diesel Fuel Pumps and Systems
• FASS Diesel Fuel Systems - Diesel Fuel Pumps and Systems

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