This comprehensive guide will walk you through the installation process of a FASS fuel system for your 5.9 Cummins engine. From disconnecting the battery to bleeding the fuel system, we’ll provide detailed instructions to ensure a smooth and successful installation.
Introduction
Upgrading your Dodge Cummins 5.9L with a FASS fuel system is a common modification for performance and reliability. FASS fuel systems are renowned for their high-flow capabilities, improved filtration, and enhanced fuel delivery, ultimately contributing to a healthier and more powerful engine. This installation guide is designed to assist you in seamlessly integrating a FASS fuel system into your Cummins 5.9L, providing you with the necessary steps for a successful installation.
Before embarking on this project, it is crucial to familiarize yourself with the specific FASS fuel system model you have purchased, as installation procedures may vary slightly depending on the series and components included. This guide will provide general instructions, but always refer to the manufacturer’s manual for model-specific details.
Installing a FASS fuel system can significantly enhance your 5.9 Cummins’s performance and longevity. By providing a consistent and ample fuel supply, it safeguards your injection pump, ensures efficient combustion, and allows for greater horsepower potential. This upgrade is a worthwhile investment for those seeking to maximize their Cummins’s capabilities and ensure its long-term reliability.
FASS Fuel System Components
The FASS fuel system for your 5.9 Cummins typically consists of several key components, each playing a vital role in the overall performance and functionality of the system. These components, carefully engineered for optimal fuel delivery and filtration, work in unison to provide a reliable and consistent fuel supply to your engine.
The heart of the FASS fuel system is the high-flow fuel pump. This pump, designed to deliver a substantial volume of fuel, ensures that your engine receives a consistent supply even under demanding conditions. It is often accompanied by a sump kit, which provides a reservoir for fuel, effectively eliminating the possibility of air being drawn into the system, leading to a smoother and more consistent fuel delivery.
The FASS fuel system also incorporates a robust filtration system. This filtration system, usually a combination of a water separator and a high-micron fuel filter, removes contaminants such as water, dirt, and debris from the fuel before it reaches your engine. This meticulous filtration process safeguards your sensitive fuel injectors and injection pump, ensuring optimal performance and extending their lifespan.
Installation Preparation
Before embarking on the installation of your FASS fuel system, it’s crucial to ensure a smooth and efficient process by meticulously preparing for the task. This preparatory phase involves gathering the necessary tools, materials, and resources, along with taking precautions to ensure a safe and successful installation.
Start by gathering all the components of your FASS fuel system. Ensure that you have all the necessary hardware, such as mounting brackets, clamps, and hose connections, readily available. Additionally, gather the appropriate tools, including wrenches, sockets, pliers, and a torque wrench, to ensure proper installation and tightening of components.
Before starting the installation, it’s recommended to consult the FASS installation manual for detailed instructions and diagrams. This manual will provide specific guidance on the installation process, including torque specifications and recommended procedures. Additionally, ensure you have a clean and well-lit workspace for easy access to all components.
Step 1⁚ Disconnect Battery
The first step in installing your FASS fuel system is to disconnect the battery. This crucial step is essential for safety reasons, as it prevents any accidental electrical shorts or sparks during the installation process. Disconnecting the battery eliminates the risk of electrical shock and ensures a safe working environment.
To disconnect the battery, locate the negative (-) terminal, typically identified by a black cable. Use a wrench or socket to loosen the nut securing the cable to the terminal. Once loosened, gently pull the cable off the terminal. Repeat this process for the positive (+) terminal, which is usually identified by a red cable.
It’s important to remember to disconnect the negative terminal first and reconnect it last to avoid any accidental sparking. This ensures that the electrical circuit is broken and eliminates the risk of unintended electrical activity during the installation process. Once both terminals are disconnected, you can safely proceed with the remaining installation steps.
Step 2⁚ Remove Existing Fuel System Components
Before installing your FASS fuel system, you’ll need to remove the existing fuel system components. This step involves carefully removing the old fuel pump, lines, and filter. Make sure to have the necessary tools, including wrenches, sockets, and a fuel line disconnect tool, on hand.
Start by locating the existing fuel pump. It’s usually mounted on the frame of your truck, near the fuel tank; Once you’ve located it, disconnect the fuel lines leading to and from the pump. Use a fuel line disconnect tool to safely detach the lines without damaging them. Be careful not to spill any fuel during this process.
Next, disconnect the electrical connector from the pump. Once all the connections are removed, you can carefully remove the pump from its mounting bracket. Finally, remove the existing fuel filter. Depending on your truck’s model, it might be located near the fuel tank or under the hood. Once you’ve removed the old fuel system components, set them aside for disposal or potential reuse.
Step 3⁚ Install FASS Fuel Pump
With the existing fuel system components removed, you can now install the FASS fuel pump. This step involves securing the pump in its designated location and connecting the fuel lines. Refer to the FASS installation manual for specific instructions and diagrams relevant to your pump model.
Start by locating the mounting bracket for the FASS pump. It might be included in the kit or you might need to purchase it separately. Securely mount the bracket to the frame of your truck, ensuring it’s level and in a position that allows for proper alignment of the pump.
Next, carefully install the FASS fuel pump onto the mounting bracket. Make sure all the bolts are tightened securely to prevent any potential leaks. If the FASS pump is a sump-style pump, ensure it’s positioned correctly and the sump is properly installed. Once the pump is mounted, connect the fuel lines leading to and from the pump. Use the provided clamps to secure the lines properly.
Before proceeding, ensure all connections are tight and free of leaks. It’s advisable to perform a visual inspection to confirm the installation is secure and that there are no loose connections or potential issues.
Step 4⁚ Connect Fuel Lines
Connecting the fuel lines is a crucial step in the FASS fuel system installation process. It involves connecting the lines from the FASS pump to the fuel filter housing and the injection pump, ensuring a secure and leak-free connection. This step is vital for the proper functioning of the fuel system.
Start by connecting the fuel line from the FASS pump to the fuel filter housing. This line is typically a high-pressure line, so ensure it’s properly secured using the provided clamps. The connection should be tight and leak-free. You may need to use a wrench to tighten the connection securely.
Next, connect the fuel line from the FASS pump to the injection pump. This line is also a high-pressure line and requires careful attention to ensure a secure connection. The line may require specific fittings or adapters, depending on the model of your FASS pump and your truck’s fuel system. Consult your installation manual for the correct fittings and procedures.
After connecting the fuel lines, inspect all connections thoroughly for any leaks. Ensure the clamps are tightened securely and the connections are free of any loose fittings. If you find any leaks, re-tighten the connections or replace any faulty fittings before proceeding.
Step 5⁚ Install Electrical Components
Installing the electrical components is a critical step in the FASS fuel system installation process. It involves connecting the FASS pump to a power source and ensuring proper grounding. This step ensures the pump receives the necessary power to operate correctly.
Locate the power source for the FASS pump. This is typically a switched ignition source, which means the pump will only operate when the ignition is turned on. Consult your FASS installation manual for the recommended power source for your specific model.
Connect the positive (+) wire from the FASS pump to the positive terminal of the power source. Secure the connection using a crimp connector or a suitable terminal. Ensure the connection is secure and free of any loose wires.
Connect the negative (-) wire from the FASS pump to a suitable ground point. A ground point is a metal surface that provides a path for electricity to flow back to the battery. Consult your FASS installation manual for recommended grounding points.
After connecting the electrical components, test the FASS pump to ensure it’s receiving power. Turn the ignition key to the ON position and listen for the pump to run. If the pump is not running, double-check the connections and ensure the fuse is intact.
Step 6⁚ Bleed Fuel System
Bleeding the fuel system is essential after installing a new FASS fuel system. This procedure removes any air bubbles that may have entered the fuel lines during installation, ensuring proper fuel flow to the engine.
Start by locating the fuel filter bleed valve. This valve is typically located on the top of the fuel filter housing. It’s designed to allow air to escape while filling the fuel lines.
Open the bleed valve by turning it counterclockwise. This will allow air to escape from the fuel system. As air is released, you may hear a hissing sound.
Next, crank the engine for a few seconds without starting it. This will draw fuel from the tank and help remove any air bubbles.
Close the bleed valve by turning it clockwise. Once the valve is closed, continue cranking the engine until it starts. If the engine doesn’t start immediately, repeat the bleeding process a few times until the engine fires.
Once the engine is running, check for any leaks from the fuel lines or connections. If there are any leaks, tighten the connections or replace any damaged components.
Congratulations! You have successfully installed a FASS fuel system on your 5.9 Cummins engine. By following these detailed instructions, you have ensured a proper and reliable installation, improving fuel flow and potentially enhancing engine performance.
Remember to regularly check and maintain your FASS fuel system, including replacing filters as per the manufacturer’s recommendations. This will ensure optimal performance and extend the lifespan of your system.
Enjoy the benefits of your new FASS fuel system, including increased fuel pressure, enhanced fuel filtration, and improved overall engine health.
If you encounter any issues or have any questions regarding your FASS fuel system, consult the manufacturer’s installation manual or contact their customer support for assistance. They can provide specific guidance tailored to your unique setup.
With a properly installed and maintained FASS fuel system, you can confidently enjoy the power and reliability of your 5.9 Cummins engine for years to come.