aFe Power dfs780 User manual

advanced FLOW engineering
Instruction Manual P/N: 42-14012
Make: GM Model: Diesel Trucks Year: 2001-2010 Engine: V8-6.6L (td) Duramax
Fuel Pressure: 8-10 PSI (Boost Operated) Supported Horsepower: 2000+

Label Qty. Description Part Number
A 1 Fuel Manifold Assembly 05-60565
B 1 Filter, Fuel 44-FF019
C 1 Bowl, Water Separator 05-60487
D 1 Bracket, Frame, Carbon Steel 05-60655
E 1 Bolt, M8 x 1.25 x 25mm 03-50442
F 1 Washer, Flat: 24mm ODxM8 ID 03-50065
G 1 Nut, Hex Nylon Lock: M8 x 1.25 03-50244
H 4 Screw, Socket Head Cap M6x1.0x50mm 03-50443
I 4 Washer, M6 (Fiber) 03-50457
J 4 Washer, M6 03-50444
K 4 Nut, Flanged Nyloc: M6 03-50445
L 2 Fitting: 3/8" NPT to AN -8 (Black) 05-60685
M 1 Harness, Stand Alone Relay 05-60551
N 1 Connector, Add-A-Harness 05-60583
O 1 Hose, Fuel Return 05-60689
P 12 Ties, Nylon Cable, 12" 05-60167
Q 1 Harness, Power 05-60523
R 1 Hose, Fuel Inlet 05-60673
S 1 Hose, Fuel Outlet 05-60681
T 1 Jumper, Priming 05-70004
Note: Legal in California for use on race vehicles only. The use of this device on vehicles used on public streets or
highways is strictly prohibited in California and others states that have adopted California emission regulations.
• Please read the entire instruction manual before proceeding.
• Ensure all components listed are present.
• Ensure you have all necessary tools before proceeding.
• Do not attempt to work on your vehicle when the engine is hot.
• Disconnect the negative battery terminal before proceeding.
• Retain factory parts for future use.
Page 2

Page 3
OAB
L
D
C
F
G
IS
E
R
Q
K
H
MNP
J
T

Step 1: Looking at the driver’s side of the truck, on the inside of the frame rail, you will see two hard
lines. These are the fuel supply and return lines for the engine. They are held in place by plastic
retainers that are bolted to the frame (shown above).
Step 2: Locate the retainer that is below the driver’s side door and is two retainers away from the fuel
cooler.
Step 3: Loosen all the stock fuel line retainers from the frame using a 13mm socket/wrench while leaving
the fuel lines in their retainers.
REMOVAL
Page 4
1
Figure 1
2 3
Refer to Figure 1 for Steps 1-3

Step 4: Gently pull the fuel lines off of the frame rail. Please be careful not to bend or kink the fuel lines.
Step 5: Place the supplied bracket between the frame and the stock fuel line retainer located in Step 2.
Step 6: While making sure the bracket is sitting on the bottom of the frame, tighten the stock fuel line
retainer.
Step 7: Tighten all the fuel line retainers.
NOTE: If the fuel line retainers are not there please use the supplied hardware to attach the
bracket to the frame.
INSTALL
Page 5
Figure 2
Refer to Figure 2 for Steps 4-7

NOTE: This is what the bracket looks like when installed correctly.
Page 6
Rear of truck
INSTALL
Figure 3

Step 8: Connect the bracket to the manifold using the four (4) supplied M6x1.0 x 50mm bolts,
M6 washers, felt washers and M6 flange nuts. The felt washers go between the pump and the
bracket.
Step 9: Tighten the manifold to the bracket.
INSTALL
Page 7
Refer to Figure 4 for Steps 8-9
Figure 4

Refer to Figure 5 for Step 10
Step 10: Turn sight glass to the desired angle and using a 1-1/4" wrench, tighten the center nut under
the DFS780 manifold.
NOTE: The pump should look like the picture above.
Figure 5
INSTALL
Page 8

Page 9
7
Refer to Figure 6 for Step 11
Step 11: Using a light oil, lube the gasket on the fuel filter before installation. Attach the supplied water
separator bowl onto the supplied fuel filter.
Figure 6
INSTALL

Figure 7
Refer to Figure 7 for Step 12
Step 12: Apply Teflon tape with (PTFE) or Teflon paste with (PTFE) to the 2 x 3/8" NPT to -8 AN fittings.
NOTE: Only apply Teflon to the NPT side of the fitting.
INSTALL
Page 10
“AN fitting” side
“NPT” side

Page 11
7
INSTALL
Figure 8
Refer to Figure 8 for Step 13
Step 13: Install the 2 x 3/8" NPT to -8 AN fittings into the DFS780 manifold (as shown above).

Page 12
7
NOTE: If you have a 2001 - 2008 truck and the fittings look like the above picture, you will need a
special tool to release the fuel line from the connectors.
You can get this tool at your local parts store.
Figure 9
INSTALL

NOTE: This is what the connections look like on the 2009 – 2010 truck.
Figure 10
INSTALL
Page 13

Page 14
7
NOTE: 2009-2010 model shown in the pictures.
INSTALL
Figure 11
Refer to Figure 11 for Step 14
Step 14: Clean the area around the fuel lines to prevent dirt and debris from going into the lines.

NOTE: 2009-2010 model shown in the pictures.
INSTALL
Page 15
Figure 12
Refer to Figure 12 for Step 15
Step 15: Disconnect the 1/2" fuel supply line.

INSTALL
Page 16
7
Refer to Figure 13 for Step 16
Step 16: Install the male quick disconnect fitting on the supplied fuel inlet hose (silver 90° “AN”
fitting- shown below) onto the female side of the stock fuel feed line.
NOTE: 2009-2010 model shown in the pictures.
Figure 13
INSTALL

Refer to Figure 14 for Step 17
Step 17: Install the female quick disconnect fitting on the supplied fuel outlet hose (black 90° “AN”
fitting - shown below) onto the male side of the stock fuel feed line.
NOTE: 2009-2010 model shown in the pictures.
Figure 14
INSTALL
Page 17
90
°
Female quick disconnect

Page 18
7
Refer to Figure 15 for Step 18
Step 18: Install the supplied inlet fuel line (90° silver “AN” fitting) onto the fuel inlet port of the
DFS780.
Figure 15
INSTALL

Refer to Figure 16 for Step 19
Step 19: Install the supplied outlet fuel line (90° black “AN” fitting) onto the fuel outlet port of the
DFS780.
Figure 16
INSTALL
Page 19

Page 20
7
Refer to Figure 17 for Step 20
Step 20: Locate the factory return line. It is located at the front of the fuel tank near the center of the
vehicle.
NOTE: 2009-2010 model shown in the pictures.
Figure 17
INSTALL
Center of truck