FASS Fuel System Installation Manual - FASS-150-DO-98-04 - Installation and Safety Guidelines

Oct 28, 2026

Installation manual for the FASS Fuel System model FASS-150-DO-98-04, specifying that the serial number on the manual package must match the box. Covers eligibility for Dodge Cummins trucks from 1998.5-2004 and provides safety and caution warnings, including securing the vehicle, drilling precautions, and not removing critical return-fuel and steel Allen head fittings. Includes package inventory, installation recommendations, parts list, and system diagram components and port functions.

LanguageEnglish

CategoryTechnology

FormatPDF

Pages14

Reading Time35 min

AccessFree to download

Safety Guidelines and Warnings

Package Components Inventory

Installation Recommendations

Contents and Parts List

System Diagram and Port Identification

Location of the FASS Fuel System

INSTALLATION MANUAL FASS FUEL SYSTEM MODEL NO. FASS – 150-DO-98-04 “HIGH PERFORMANCE FUEL DELIVERY SYSTEM” FASS FUEL SYSTEMS BY: DIESEL PERFORMANCE PRODUCTS, INC. 905 CAMELOT ACRES DR. VILLA RIDGE, MO 63089 TELEPHONE 1-636-742-3100 FAX 1-636-742-3103 WARNING!! Installing the improper FASS Fuel System or installation kit can cause severe engine damage. This installation manual applies to the FASS-150-DO-98-04 contained in the same package. The serial number on the installation/owners manual package should match the serial number on the outside of the box. If it doesn’t, call the factory. This FASS-150-DO-98-04 applies to this application: The Dodge Cummins Truck 1998.5-2004 SAFETY GUIDELINES AND WARNINGS! WARNING! SECURE VEHICLE FROM ROLLING! WARNING! Use care not to drill into any electrical wires, air lines or other damageable components when drilling. WARNING! Consult vehicle manufacturer’s instructions concerning the electrical system before attempting any electrical connections. CAUTION: Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel. CAUTION: Properly secure lines to prevent chaffing. VERY IMPORTANT: THE RETURN FUEL FITTING LOCATED IN THE BASE OF THE FASS FUEL SYSTEM SHOULD NOT BE REMOVED. THEREIS A SPECIAL CUT IN THIS FITTING THAT ASSISTS IN REGULATING PRESSURE. ALSO, DO NOT REMOVE ANY STEEL ALLEN HEAD FITTINGS. THESE PORTS WERE USED IN THE MACHINING PROCESS. INSTALLATION MANUAL Welcome to the FASS Fuel/Air Separation System. A full color installation manual is [available at our website www.dieselpp.com](available at our website www.dieselpp.com). The installation of the FASS FUEL SYSTEM can be relatively simple when the following steps are followed. 1. Inventory the package components completely. Notify Diesel Performance Products, Inc. Immediately of any parts missing or damaged. 2. We have invested many hours into the development of the installation and owner’s manual’s to simplify the installation and operation of the FASS Fuel System®. Please read the owner’s manual and the installation manual completely. Understand how the system operates and installation recommendations before beginning installation. Most of the questions that you will have will be answered in one of these manuals. If you have a question please review the installation or owner’s manual. 3. The installation recommendations contained herein are suggested installation guidelines only. Each installation can and may vary considerably because of the many options and accessories available to the truck market. Installation personnel should use good judgment and common sense when installing the FASS Fuel System. If any installation procedure is uncertain, first contact your authorized FASS Fuel Systems dealer. If your dealer cannot help you, contact Diesel Performance Products, Inc. Due to training, communication and our relationship we have with our authorized dealers we recommend an authorized FASS Fuel Systems dealer for the installation of the FASS System. They are prepared to install the FASS System with the most efficiency. If a situation/problem arises during the installation they are most prepared for that situation/problem. It may take more time for an unauthorized shop to address the situation/problem. We will not be responsible. For the 2 year warranty please fill out the “PRODUCT REGISTRATION FORM”and attach a copy of the sales receipt. This must be done within 30 days of the purchase or the 2 year warranty will not be valid. Contents Include: Description Quantity Part \# 1. Pump/Filtration Unit -- -- -- -- 1 -- FASS-150 2. Fuel Pump Bracket -- -- -- -- 1 -- BR-1001 3. Owners Manual-- -- -- -- 1 -- OM-1001 4. Electrical Harness -- -- -- -- 1 -- WH-1002 5. 3/8” Fuel Line -- -- -- -- 17’ -- FL-1001 6. ¼“ mounting bolts, washers -- -- -- 4 ea. -- -- -- and nuts. 7. 3/8“ mounting bolts, washers -- -- -- 6 ea. -- -

FAQs

Are any fittings prohibited from removal during installation?

Do not remove the return fuel fitting located in the base of the FASS Fuel System, as it contains a special cut to regulate pressure. Do not remove any steel Allen head fittings, including those used during machining.

Oct 28, 2026

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