FASS Titanium Signature Series Installation Instructions: An Overview
FASS systems, including the Titanium Signature Series, require careful installation for optimal performance. These instructions detail preparation, mounting, wiring, and post-installation checks.
Understanding the FASS System
FASS (Fuel Air Separation System) technology revolutionizes diesel fuel delivery, ensuring a consistent supply of clean, air-free fuel to your engine. The Titanium Signature Series builds upon this foundation with enhanced filtration and a robust pump design. This system addresses common diesel issues like fuel aeration and contamination, improving performance and extending component life. By separating air and water, FASS maximizes fuel efficiency and protects sensitive injection systems. Proper installation, as outlined in these instructions, is crucial for realizing these benefits.
Components Included in the Signature Series
The FASS Titanium Signature Series package contains a high-flow titanium fuel pump, a pre-filter, and a secondary filter with varying micron ratings for comprehensive fuel cleaning. You’ll also find a fuel level sending unit, necessary mounting brackets, and pre-bent fuel lines for simplified installation. Electrical components, including a wiring harness and relay, are included for seamless integration. Verify all listed components are present before beginning the installation process to avoid delays.
Pre-Installation Considerations
Before starting, confirm vehicle compatibility and gather required tools. Prioritize safety by disconnecting the battery and relieving fuel system pressure.
Vehicle Compatibility Check
Ensuring proper fitment is crucial before beginning the installation process. Verify your vehicle’s year, make, and model against the FASS Titanium Signature Series compatibility list, available on their official website or through authorized dealers. Confirm sufficient space for pump mounting, considering potential interference with existing components like the fuel tank, frame rails, or exhaust systems.
Double-check fuel line sizes and connections to guarantee compatibility with the FASS system’s fittings. Incorrect sizing can lead to leaks or reduced fuel flow. If unsure, consult a qualified mechanic or FASS technical support for assistance.
Tool Requirements
Successful installation demands specific tools. You’ll need a socket set (metric and standard), wrenches, screwdrivers (Phillips and flathead), fuel line disconnect tools appropriate for your vehicle, and a wire stripper/crimper. A multimeter is essential for electrical connections, alongside safety glasses and gloves.
A drill with various bits may be required for mounting, plus a hole saw if modifications are needed. Consider having penetrating oil, Teflon tape, and a fuel-resistant sealant readily available. Proper tools prevent damage and ensure a secure installation.
Safety Precautions
Prioritize safety during installation! Disconnect the vehicle’s battery to prevent electrical shorts. Work in a well-ventilated area, as fuel vapors are flammable and hazardous. Wear safety glasses to protect your eyes and gloves to shield your skin from fuel and chemicals.
Never work on a fuel system near open flames or sparks. Have a fire extinguisher readily available. Properly dispose of old fuel and filters according to local regulations. If unsure about any step, consult a qualified mechanic.
Installation Process: Fuel System Preparation
Begin by safely accessing the fuel tank and preparing the area for fuel line disconnection, ensuring a clean and secure workspace.
Fuel Tank Access and Preparation
Prior to any work, ensure the vehicle is parked on a level surface and the parking brake is firmly engaged. Disconnect the negative battery cable to prevent accidental electrical shorts. Carefully locate the fuel tank and identify the access points for fuel line connections. Depending on the vehicle, this may involve removing undercarriage panels or accessing the tank through an inspection port.
Thoroughly clean the area around the fuel tank to remove any dirt, debris, or potential ignition sources. Have appropriate spill containment materials readily available, such as absorbent pads or a drip pan, to manage any fuel spillage during line disconnection. Proper preparation minimizes risks and ensures a clean installation.
Fuel Line Disconnection
Before disconnecting any fuel lines, relieve the fuel system pressure according to your vehicle’s service manual. Carefully disconnect the fuel supply and return lines (if equipped) from the factory fuel tank. Use appropriate line wrenches to avoid damaging the fittings.
Be prepared for some fuel spillage, even after pressure relief. Have absorbent materials readily available; Label each line clearly to ensure correct re-connection later. Inspect the fuel lines for any signs of damage or deterioration; replace them if necessary. Proper disconnection prevents fuel leaks and ensures a safe installation.
Mounting the FASS Titanium Pump
Select a secure location for the pump, ensuring adequate ventilation and accessibility. Use the provided mounting bracket and hardware for a stable installation.
Pump Location Selection
Carefully consider the pump’s location, prioritizing accessibility for future maintenance, like filter changes. Ensure sufficient space around the unit for fuel line connections and wiring. Avoid areas exposed to extreme heat sources or direct engine exhaust.
The mounting surface must be structurally sound to support the pump’s weight, especially when full of fuel. Vibration dampening is crucial; consider using rubber isolators between the pump and the mounting surface to minimize noise and prevent stress on fuel lines.
Proximity to the fuel tank is ideal to reduce fuel line length, but safety and accessibility remain paramount.
Secure Mounting Procedures
Utilize the provided mounting brackets and hardware, ensuring they are compatible with your vehicle’s frame. Drill pilot holes before installing bolts to prevent splitting or damaging the mounting surface. Employ thread-locking compound on all fasteners to resist vibration loosening.
Verify the pump is firmly secured and doesn’t exhibit any wobble or movement. Double-check all bolts are tightened to the manufacturer’s specified torque.
Consider adding additional support if the mounting location is prone to excessive vibration or stress. A secure mount is vital for preventing fuel leaks and ensuring long-term reliability.
Wiring and Electrical Connections
Proper electrical connections are crucial for safe and reliable operation. Connect the power source, ground, and wiring harness according to the diagram provided.
Power Source Connection
Identify a suitable power source capable of supplying the FASS Titanium pump’s required voltage and amperage. Typically, this involves connecting to the vehicle’s battery or a dedicated power distribution block. Ensure the chosen power source is clean and reliable to prevent damage to the pump’s sensitive electronics. Use appropriately sized wiring and secure connections, employing a fuse or circuit breaker inline for safety. Double-check polarity before connecting to avoid irreversible damage. A properly connected power source is fundamental for consistent pump operation and longevity.
Grounding Instructions
Establishing a solid ground connection is crucial for the FASS Titanium system’s performance and safety. Locate a clean, unpainted metal surface on the vehicle’s chassis, as close to the pump as possible. Use a heavy-gauge grounding wire, securely fastened with a corrosion-resistant connector. A poor ground can cause electrical interference, reduced pump efficiency, and potential damage to the system’s components. Verify the ground connection’s integrity with a multimeter to ensure low resistance. Proper grounding minimizes electrical noise and ensures reliable operation.
Wiring Harness Routing
Route the FASS Titanium’s wiring harness carefully, avoiding hot engine components, sharp edges, and moving parts. Secure the harness with zip ties or loom tubing at regular intervals to prevent chafing and damage. Keep the wiring away from the fuel lines to avoid potential fuel contamination or ignition hazards. Ensure sufficient slack is maintained throughout the harness length to accommodate engine movement and vibration. Proper routing protects the wiring and ensures a reliable electrical connection for optimal system function.
Fuel Line Connections
Proper fuel line connections are crucial for a leak-free and efficient FASS system. Ensure all fittings are secure and compatible with diesel fuel.
Inlet Fuel Line Installation
Begin by carefully connecting the inlet fuel line to the FASS pump’s designated inlet port. Utilize the provided fittings, ensuring a tight and secure connection to prevent fuel leaks. Double-check compatibility with your vehicle’s existing fuel lines.
Consider using new fuel line if the original is aged or damaged. Proper clamping is essential; employ high-quality fuel line clamps designed for diesel applications. Route the inlet line to avoid sharp bends or potential abrasion points, maintaining a smooth flow path for optimal pump performance.
Outlet Fuel Line Installation
Connect the high-pressure outlet fuel line from the FASS pump to the fuel rail or injection pump, utilizing the supplied fittings. Ensure a secure, leak-proof connection, as this line carries fuel at significant pressure.
Verify the outlet line’s routing avoids heat sources and moving parts. Employ appropriate fuel line protection sleeves where necessary. Double-check clamp tightness and line integrity after installation. Proper installation guarantees consistent fuel delivery and optimal engine performance, preventing potential fuel starvation issues.
Return Line Installation (if applicable)
If your engine utilizes a fuel return system, connect the return line from the fuel rail or injection pump to the designated return port on the FASS Titanium pump. Ensure a secure and leak-proof connection using the provided fittings.
Route the return line carefully, avoiding kinks or restrictions that could impede fuel flow. Proper return line installation is crucial for maintaining consistent fuel pressure and preventing fuel aeration within the system, contributing to optimal engine operation.
Post-Installation Checks and Priming
After installation, thoroughly inspect all fuel line connections for leaks. Prime the system to remove air, ensuring consistent fuel delivery for optimal engine performance.
Leak Inspection
Following the installation of your FASS Titanium Signature Series, a meticulous leak inspection is paramount. Start the engine and carefully examine all fuel line connections – at the fuel tank, pump inlet/outlet, and any associated fittings. Pay close attention to the fuel filter housing and ensure a tight seal.
Visually inspect for any signs of fuel droplets or dampness. Gently feel around connections (avoid direct contact with fuel!) to detect any fuel mist. If leaks are identified, immediately shut off the engine and rectify the issue before proceeding. A thorough inspection prevents potential fire hazards and ensures optimal system performance.
System Priming Procedure
After verifying all connections are secure, initiate the FASS Titanium Signature Series priming procedure. Turn the ignition key to the “on” position, but do not start the engine. Allow the pump to run for approximately 30-60 seconds, observing the fuel pressure gauge (if equipped).
This process eliminates air from the fuel lines and ensures the system is fully primed. If the pump doesn’t prime within this timeframe, re-check all connections and repeat the process. Once primed, start the engine and monitor for smooth operation and consistent fuel pressure.
Troubleshooting Common Issues
Addressing problems like pump failure to prime, fuel leaks, or electrical malfunctions is crucial. Careful diagnosis and adherence to safety protocols are essential.
Pump Not Priming
If the FASS Titanium pump fails to prime, initially verify the power supply and grounding connections are secure. Inspect the inlet fuel line for obstructions or kinks, ensuring a consistent fuel flow to the pump. Check the fuel filter for excessive contamination; a clogged filter restricts flow and prevents priming.
Air trapped within the system can also hinder priming. Cycle the ignition key several times to allow the pump to attempt priming, and bleed any air from the system using the provided bleed valve. Confirm the fuel tank has sufficient fuel volume. Persistent issues may indicate a faulty pump or a problem within the fuel delivery system.
Fuel Leaks
Immediately address any fuel leaks detected after FASS Titanium installation. Carefully inspect all fuel line connections – inlet, outlet, and return (if equipped) – ensuring they are tightly secured and properly clamped. Examine the pump housing and filter canister for cracks or damage.
Tighten fittings as needed, but avoid over-tightening, which can strip threads. If leaks persist, replace the affected fuel lines or fittings. A leak near the fuel filter may indicate improper installation or a damaged filter seal. Discontinue operation until leaks are fully resolved to prevent fire hazards.
Electrical Problems
Troubleshooting electrical issues with your FASS Titanium system begins with verifying the power source connection and grounding. Ensure the power wire is securely connected to a switched power source and the ground wire is firmly attached to a clean, unpainted metal surface on the vehicle’s chassis.
Check the wiring harness for any damaged or frayed wires. A blown fuse is a common culprit; replace it with a fuse of the correct amperage. If the pump still doesn’t operate, test the voltage at the pump connector to confirm power delivery.
Maintenance and Filter Replacement
Regular filter changes are crucial for maintaining optimal FASS system performance. Scheduled cleaning and timely replacements ensure consistent fuel flow and protect the pump.
Filter Replacement Schedule
Maintaining a strict filter replacement schedule is paramount for the longevity and efficiency of your FASS Titanium Signature Series system. Generally, the primary filter should be replaced every 15,000 miles or 12 months, whichever comes first. Secondary filters, if equipped, typically require replacement every 30,000 miles or 24 months.
However, operating conditions significantly impact this schedule. Frequent off-road driving, exposure to contaminated fuel sources, or consistently harsh environments necessitate more frequent filter changes – potentially halving the recommended intervals. Always monitor filter pressure and inspect filters regularly for excessive dirt or debris accumulation to determine if an unscheduled replacement is needed.
Cleaning Procedures
Regular cleaning of the FASS Titanium Signature Series housing and surrounding areas prevents contaminant buildup and ensures optimal system performance. Disconnect the power source before commencing any cleaning. Use a mild detergent and water solution to wipe down the exterior of the pump and filter housing.
Avoid harsh chemicals or abrasive cleaners that could damage the components. Inspect and clean the mounting area, removing any dirt, debris, or fuel residue. Periodically check and clean electrical connections to prevent corrosion. Ensure all components are completely dry before restoring power.
FASS System Specifications
FASS Titanium Signature Series boasts high flow rates, precise micron filtration, and operates within a standard 12/24V range, ensuring reliable diesel fuel delivery.
Pump Flow Rate
FASS Titanium Signature Series pumps are engineered to deliver substantial fuel flow, crucial for high-performance diesel engines and demanding applications. Specific flow rates vary based on the model selected within the series, but generally exceed industry standards. Expect rates capable of supporting significantly increased horsepower levels, often surpassing 100 gallons per hour (GPH).
This robust flow capacity ensures adequate fuel supply even under extreme load conditions, preventing fuel starvation and maintaining optimal engine performance. Accurate flow rate data for each specific pump model can be found in the detailed product specifications provided with your unit.
Filter Micron Ratings
FASS Titanium Signature Series systems utilize a multi-stage filtration process, employing varying micron ratings to effectively remove contaminants. The primary filter typically features a 2-micron rating, capturing fine particles that can damage sensitive fuel injectors. A pre-filter, often around 30-micron, removes larger debris, extending the life of the primary filter.
These precise micron ratings ensure exceptionally clean fuel delivery, safeguarding engine components and maximizing performance. Regularly replacing filters according to the maintenance schedule is vital for maintaining optimal filtration efficiency and preventing fuel system issues.
Operating Voltage
FASS Titanium Signature Series fuel pumps are designed to operate efficiently within a 12-volt DC electrical system, commonly found in most diesel-powered vehicles. The acceptable voltage range is typically 11.5 to 16 volts to ensure reliable performance and prevent damage to the pump’s electrical components.
Consistent voltage is crucial; significant fluctuations can reduce pump output and lifespan. Proper grounding and a dedicated power source are essential for maintaining stable operating voltage and maximizing the system’s benefits.