aFe Power dfs780 User manual

advanced FLOW engineering DFS 780
Instruction Manual P/N: 42-14011
Make: GM Model: Diesel Trucks Year: 2001-2010 Engine: V8-6.6L (td) Duramax
Fuel Pressure: 8-10 psi (relay controlled)

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 Relay 05-60551
N 1 Connector, Add a harness & Fuse 05-60583
O 1 Hose, Fuel Return 05-60689
P 12 Ties, Nylon Cable, 12" 05-60167
Q 1 Harness, Power 05-60632
R 1 Hose, Fuel Inlet 05-60673
S 1 Hose, Fuel Outlet 05-60681
• Please read the entire instruction manual before proceeding.
• Ensure all components listed are present.
• If you are missing any of the components, call customer support at 951-493-7100.
• 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.
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AB
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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 (labeled as “2” above).
Step 3: Remove the nuts from the backside of the three (3) stock fuel line retainers (leave the
fuel lines in their retainers.
REMOVAL
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1
Figure 1
2 3

Step 4: Gently pull the fuel lines/retainers off of the frame rail. Be careful not to bend or kink the
fuel lines.
Step 5: Place the supplied carbon steel frame bracket between the frame and the stock fuel
line retainer located in Step 2.
Step 6: While making sure the carbon steel frame bracket is sitting on the bottom of the frame,
reinstall and tighten the factory nuts removed in Step 3.
NOTE: If the fuel line retainers are not there please use the supplied hardware to attach
the bracket to the frame.
• (1) M8 x 1.25 x 25mm bolt
• (1) M8 washer
• (1) M8 locknut
INSTALL
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Figure 2

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

Step 7: Mount the supplied fuel manifold assembly to the carbon steel frame bracket using the
supplied hardware and tighten.
• (4) M6x1.0 x 50mm bolts
• (4) M6 washers
• (4) M6 fiber washers
• (4) M6 flanged locknuts
NOTE: The fiber washers go between the fuel manifold assembly and the carbon steel
bracket.
INSTALL
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Figure 4

Step 8: Turn sight glass to the desired angle and using a 1-1/4" wrench, tighten the center nut
under the fuel manifold.
NOTE: The pump should look like the picture above.
Figure 5
INSTALL
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Step 9: Using a light oil, lube the gasket on the supplied fuel filter and install on the fuel
manifold assembly. Thread the supplied water separator bowl onto the fuel filter.
Figure 6
INSTALL

Step 10: 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.
Figure 7
INSTALL
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“AN fitting” side
“NPT” side

Step 11: Install the 2 x 3/8" NPT to -8 AN fittings into the fuel manifold assembly (as shown
above).
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7
Figure 8
INSTALL
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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

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NOTE: This is what the connections look like on the 2009 – 2010 truck.
Figure 10
INSTALL
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Step 12: 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.
Figure 11
INSTALL

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Step 13: Disconnect the 1/2" fuel feed line.
NOTE: 2009 -2010 model shown in the pictures.
Figure 12
INSTALL
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Step 14: Install the straight male quick disconnect fitting on the supplied fuel inlet hose (silver
90° -8 AN fitting - shown below) into the female side of the stock fuel feed line.
NOTE: 2009 - 2010 model shown in the pictures.
INSTALL
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Figure 13
INSTALL

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Step 15: Install the 90° female quick disconnect fitting on the supplied fuel outlet hose (black 90° -8 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
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90
°
Female quick disconnect

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Step 16: Locate the factory fuel return line. It is located at the front of the fuel tank near the
center of the truck.
NOTE: 2009 - 2010 model shown in the pictures.
Figure 15
INSTALL
Center of truck

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Step 17: Disconnect the stock fuel return line.
NOTE: 2009 - 2010 model shown in the pictures.
Figure 16
INSTALL
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Step 18: Install the straight male quick disconnect fitting on the supplied fuel return hose (
shown below) into the female side of the stock fuel return line.
NOTE: 2009 - 2010 model shown in the picture
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Figure 17
INSTALL