Fass FA D10 220G User manual

INSTALLATION MANUAL
APPLICATION:
FA D10 220G (220GPH @ 45psi)
FA D10 240G (240GPH @ 45PSI)
Cummins 5.9L 12 Valve
*with P7100 Injection pump*
**bypassing the factory lift pump**
1994-1998

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 em-
ploy 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 commit-
ment and will continue this practice to support America! Our competition is doing exactly the op-
posite 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 ingre-
dients to insure you are running with the “Highest-Quality” fuel system in the world! We have im-
plemented 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 prod-
uct 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 Install manual for full Limitations 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 un-
used 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.

FASS Recommended Application
FA D10 220G Cummins(12 Valve) 1994-1998 with extreme horsepower
modifications
FA D10 240G Cummins(12 Valve) 1994-1998 with extreme horsepower
modifications
¡WARNINGS!
 Read all instructions before starting installation of this product!
 Installing the improper FASS Pump can cause severe engine damage.
 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
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.
Serial #

(FA D10 220G or FA D10 240G)
(FA D10 220G or FA D10 240G)
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 effi-
ciency. 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 [email protected] 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
Serial # Found

220 or 240 GPH
45 PSI (Approximately)
Adjustable Fuel Pump Series
A fuel pressure gauge is highly recommended to identify fuel filter life and to prevent engine damage!
“E”
To Engine
‘T’
Fuel Inlet Port
Boost
Compensation
Port
Adjustment Lock Nut
Set screw
Fuel Pressure Port
Installation
Step 1: Install Electrical Harness
Step 2: Prepare Suction Line
Step 3: Mount Fuel System
Step 4: Install Fuel Line
Step 5: Check/Set Pressure
Step 6: Check Installation

Contents
FL-1002 x14’
WH-1005
MP-9037
BHB-1001
THB-1001
FF-3248
FPB-2005

HC-1001
10-300
PL-1005
Ring Terminal
BHF-1002
PL-1004
ST-1005Px16”
BHN-1001 OR-223
LW-1001
DIPF-1003
RS-1002
1/2” Plug
PL-2003
*Cable Ties*
46044
Mounting Package Contents
4 1/4 - 20x1.75”
1/4” Nut 1/4” washer
2 1/4 - 20x1.5”
RS-2001
46260

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.
FUSE
RELAY
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 add-a-fuse
and the WH-1005.
B. Place wire from 46044 and WH-1005 into butt connector. Using crimping tool connect 46044 and WH-
1005 with butt connector. Install 46260 to 46044 bottom slot (opening that is near the spade). Route
Add-a-fuse lead through the fire wall using existing grommet. The use of corrosion preventative
spray is recommended.

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 pan-
el.
G. Route WH-1005 wire harness along frame rail to mounting location of pump. Completion of this step
will be addressed in the Mounting Step 3.
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.

C. Disconnect the factory suction and return line. The factory lines are re-
moved by pressing in on the two tabs located in the connecting fuel line.
Keep the tab on the factory fuel lines.
D. Disconnect the factory electrical harness on top of the fuel tank.
E. With the fuel tank empty of fuel, remove it from the vehicle.
F. Clean the fuel module area then remove the lock ring on the top of the fuel
tank.
G. Once the lock ring is removed, remove pick up module from fuel tank. Be
careful not to bend the fuel sending arm.
B. Remove the filler neck and overflow tubes from the truck by loosening the
clamps at both ends.
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 center of the fuel tank, front to back
and left to right, the more usable fuel there will be!
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
Some of the photo’s are of a different application, procedures are the same.
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.

I. Before drilling marked location, clean area of debris. Using the photo,
double check area selected for any interference including the fuel level
L. 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. Using a razor knife make
multiple cuts to insure proper length, it is easy to shave the suction tube
with the razor.
M. With proper length being obtained, place the assembly into the drilled
hole securing the assembly using the lock washer & nut. Tighten Nut.
Loctite may be applied to the threads of the BHF-1002 for added insur-
J. Drill a 1 3/8” hole, catching all debris. De-bur hole and remove any
missed debris in the fuel tank.
K. VERY IMPORTANT: Support fuel tank on both ends allowing the nat-
ural formation of the tank to take place. Failure to perform this step can
and will create an issue with less usable fuel!
H. Assemble the BHF-1002 with the PL-1004 in port “S” using thread
tape, the 1/2” plug in port “R” along with pushing the ST-1005P onto
the barb portion of the BHF-1002. Insert O-ring into groove. Torque to
40ft/lbs.

P. Connect factory wire harness to the fuel module along with the factory
fuel lines.
O. Route fuel line over the frame rail while reinstalling the fuel tank. Torque tank hanger bolts to proper
specifications.
Q. Reattach filler neck and clamps.
FASS harness
N. Carefully reinstall install pick up module making sure the leveling arm
is not obstructed by the suction tube. Reinstall factory lock ring.

B. Secure THB-1001 to bolt on bracket with the RS 1002 and the (2)– 1/4-20x1 bolts, 1/4 washers, and 1/4
nuts. With the (4)-1/4-20x1.75” bolts thread the BHB-1001 to the THB-1001.
A. Locate bed bolt and remove the bolt. Position RS-2001 between FPB-2005 and truck bed.
C. 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
Note: Use of Anti-seize compound is highly recommended.

D. 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 MANU-
FACTURES WARRANTY.

A. Route fuel line to the suction port on the FASS pump labeled
“T”. Cut the fuel line. Insert PL-1005 into fuel line using oil. At-
tach to 10-300 in ‘T’ port. Torque to 18 ft./lbs.
C. Insert PL-1005 into fuel line. Attach to 10-300 located in the
port labeled “E”. Use oil. Torque to 18 ft./lbs. Route this line to
the inlet port of the factory filter housing.
B. Install in-line fuel filter in an accessible location in the suction
line using the HC-1001’s. Make sure the fuel flows in the direc-
tion of the arrow on the canister.
D. Measure and cut fuel line. Insert PL-2003 90° Push-Lok fitting
using oil.
E. Disconnect factory fuel line and injector return line from inlet
side of the factory fuel filter and install the DIPF-1003. Torque to
18 ft./lbs.
Do Not use sealant on AN (male flare) fittings. Only use sealant on threads installed into pump assembly.
Note: Inline filter will need to be replaced every 6,000 miles.

F. Attach the PL-2003 to DIPF-1003. Torque to 18 ft./lbs.
G. Remove banjo bolt connecting the outlet line of the factory fuel filter. This is the line in front of the
inlet line removed in step f.
H. Move the injector return line from step f and stack on top of the outlet line of the factory fuel filter.
Light bending will be required, be very careful not to kink or crack this fuel line. Install the Banjo Bolt
removed in step f. Torque to 18 ft./lbs.
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 45 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 pressure.
 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.
 Check for leaks.
 Start the engine
 Recheck all fluid and filter connections for leaks
 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 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 recom-
mend you to the nearest dealer.
Diesel Performance Products, Inc. (hereafter “SELLER”) gives Limited Warranty as to description, quality, merchantabil-
ity, fitness for any product’s purpose, productiveness, or any other matter of SELLER’S product sold herewith. The SELL-
ER 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 in-
curred 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 Prod-
ucts, 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
636-433-5410