FASS Install tips for third gen please

[Yo Hoot]

I have the full setup on the way and am installing it on my 2004. Any tips would be helpful and are there fuel line or other upgrades I should do while I'm at it?



Thanks!

 

[jray]

Tips:



Use the fuel line that comes with the kit, its good stuff.



When you to mount the pump bracket/hanger to the rear leaf spring perch, make a template out of cardboard of the three holes on the bracket/hanger. Use the template to mark the spring perch prior to drilling it.



Bypass the stock filter and plumb directly into the injector pump or you can buy the parts to plumb it directly into the old canister but really the stocker is no longer needed. If you choose to go directly into the pump be very careful to avoid getting any dirt in the pump.



Good luck, It's fairly easy, just take your time.

 

[Yo Hoot]

Will I need to drop the tank?

 

[jray]

There's no need to drop the fuel tank. You can reach the top of the tank from the drivers side rear wheel well area. Theres a coupler - slip type fitting ( akin to an air hose type fitting ) for the fuel line that the factory uses which you disconnect. The FASS kit comes with a new coupler.



Also just a little clarification: Are you using a FASS fuel pump and not the companys HPFP? The HPFP has no filter and it requires the use of the factory fuel filter. The FASS has a fuel filter and a water separator. Just want to make sure you have the filter type model. Too many people have bought the HPFP and have referred to it as a FASS. I"d hate to see you make a mistake and run with no filter.



One more tip. The FASS pumps and cycles alot of fuel. If you are considering running a 3 micron filter which most recommend for 3g trucks you might consider running the 10 micron filter that comes in the kit for a few thousand miles while it removes the big contamanants from your tank. Besides its no worse than the filter 10 micron that your truck came with. You could however attempt to sell the 10 micron filter and just start off with a 3 micron filter to begin with.

 

[Yo Hoot]

Good stuff.



It's the full system, filters and all.



I inquired about the filters... . I would have liked if you could specify the filter media upon ordering but you cannot. I ordered a couple of extra 3mic filters for the change. I probably will go right to the 3m from the start.

 

[Yo Hoot]

OK I did a quick trial fit. I looks like the big FASS bracket hits the fender support. Is it just a close fit or do I need to trim the bracket?



Doing this job tomorrow. Tank is empty and I'm going to drop it because I have the original vent mod with the tank fitting that never sealed properly. Will install the newer version that I've had sitting around for two years.

 

[Axion]

I had to trim my mounting bracket to get the filters where I wanted them. I dropped the factory tank to install the FASS draw straw. I upgraded the feed hose from the draw straw to the FASS intake to a 1/2" line. I used Aeroquip hose with barb fittings and had no problems. I did find the barb fittings that came with the kit took a lot of work to seat completely and yes I did dip the hose and the barbed fitting in clean engine oil prior to installing the fitting.

The first picture is of the completed installation and the portion of the bracket I had to remove highlighted. I found that the portion removed would interfere with the radius of the spring hanger.

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If I moved the bracket up enough to sit flat, I had clearance issues with the pump installed.

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The last picture is kind of hard to see but the highlighted section shows a small portion of the gusset I had to remove. Again with the gusset complete the outer edge of the filters rubbed against the lower lip of the fender sheet metal.

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Overall I could not be happier with my install. Had to make a couple of trips to the parts store but thats half the fun. I can now plan future upgrades without having to worry about fuel delivery. I also don't have to worry about dirty fuel with the 3 micron filter cleaning things up. I changed a couple of other things for my install. Let me know and I can send some more pics if anyone is interested.

 

[jray]

My bracket actually touches the fender support after installation. Doesn't create a problem and I didn't grind the bracket at that location. I did have to grind the pump bracket on the gusset due to a clearance problem with the spring perch.





LOL When I started typing this response to your question Axion hadn't yet given his post with pictures. After I hit the send button I saw he had submitted a post and provided photos. In looking at his last photo, I see that he too had to grind the fuel pump bracket at the gusset in order to clear the spring perch.

 

[Axion]

I clear the fender sheet metal near the bottom of the filters by just shy of 1/4". The fender support rod looks a lot closer in the picture than it is. Probably just over 1/4".



I took the rear fender well liner and the fender support rod out for installation. I had forgotten about the rod during my test fits and just got lucky that it cleared!

 

[Yo Hoot]

You fellows are awesome. Doing mine now. Printing the pics out.

 

[steved]

The only issue I had with the install in my 04. 5 was the top of the FASS is hitting the fuel filler hose... I had no other interferences.



steved

 

[Yo Hoot]

Well I finished up today. Took me two days. Yesterday I had to drop the tank because I had the original design tank vent with the crappy brass fitting with the o-ring. Been leaking and seeping for over two years. Even failed state inspection once because of the leak.

So I got the tank done yesterday and cut the bracket per Axion's pictures.

Today I bolted everything up. Axions pictures sure made my day because I was able to locate the unit with nothing touching. Sure is a close fit.

Took quite a while getting fuel sucked up into the pump. Probably ten key starts before I even heard the pump change it's tune. Probably twenty keystarts to get her running. Might have helped to fill the filters with fuel bit too much risk of contamination.

So I hop in the truck... effin fuel gauge wasn't working. I was livid, All I could think about was I damaged the float/sensor. Than I remembered using the floor jack to loft the tank... thinking I damaged the whole canister... possibly even crushed it inside the tank.

Got home and stuck my hand up there... . I forgot to reconnect the harness to the sensor. I was relieved... looked agian... still not working. Got under again and seated it while wiggling it... . that did it. All good.

Thanks again to everyone that took the time to take pics and help out!



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[Yo Hoot]

Suppose I want to monitor fuel pressure now. What are some ways to do it?

 

[liberty]

Yo hoot, looks like you take good care of your truck, i was impressed at the condition of your frame and inside the wheelwell. Thats imaculate for an '04!

Nice job on the FASS install too, Thanks for posting lots of pics.