Description

FASS 150/95-1007, 150/150-1007 Installation Manual

You have a diesel truck with a FASS Fuel Air Separation System waiting to go in, or one that’s already in and throwing codes because somebody used a generic aftermarket how-to. I’ve seen that happen more times than I care to count. A fuel system that pulls air or loses prime because the lines were run wrong or the pump mounting bracket had the wrong bolt torque. The difference between a clean install and a headache that costs you a weekend is having the actual FASS 150/95-1007, 150/150-1007 Installation Manual open on the bench. Not a photocopy of a photocopy. Not a forum post. The factory manual from Diesel Performance Products, Inc.

FASS 150/95-1007 and 150/150-1007: What the Installation Manual Covers

This is a 19-page document, and every page counts. Page 1 identifies the models—150/95-1007 and 150/150-1007—and lists the Fleetguard filters you’ll be dealing with: the HF6604 and FS1023. If you’re swapping filters, you need those part numbers right there. The manual walks you through mounting orientation, fuel line routing (inlet and outlet), and the electrical connections for the pump and the controller. There’s a priming procedure that has to be followed in order, or the pump will run dry and you’ll replace it under warranty if you’re lucky, out of pocket if you’re not.

Mounting and Fuel Line Routing: Factory Procedure

The bracket goes where? The manual shows you the exact position for the pump relative to the fuel tank. Too high and you get cavitation. Too low and you risk picking up debris. The line from the tank to the filter head needs to be -6 AN or equivalent, with a minimum bend radius that’s specified. Don’t guess. The factory drawing in this Installation Manual gives you the clearances and the recommended hose clamps. Skip a clamp and you’ve got a fuel leak on a hot turbo. Not a joke.

Do Not Skip the Priming Procedure

Air in a common-rail system kills injectors. The manual has a specific sequence for bleeding air from the system before first start. You’ll need a scan tool to cycle the fuel lift pump? No. The FASS system has its own prime function. The book tells you the key-on, key-off timing. Do it wrong and the pump may run but not build pressure. Page 2 of the manual includes the steps to customer satisfaction—read it before you call tech support. They will ask you if you followed that page. I know because I’ve been on that phone call.

3 Filters You Will Deal With

Two Fleetguard filters are listed: the HF6604 (water separator/fuel filter) and the FS1023 (secondary filter). The manual covers their replacement intervals and the correct torque for the filter housing caps—over-torque and you crack the plastic bowl. Under-torque and you get a leak that lets air in. There’s also a third filter? Not in this manual, but some applications add a pre-filter. The manual tells you where to install one if your truck requires it, and what micron rating is acceptable.

Warranty and Troubleshooting: Page 2 and Beyond

Diesel Performance Products includes a warranty registration form inside the manual. Fill it out and send it within 30 days or the warranty is void. The troubleshooting section (pages 14-16 based on the index) lists low pressure, no flow, and electrical issues with diagnostic steps. Each step references a specific component and test voltage. No vague suggestions. If the pump doesn’t run, check the relay and the fuse—both are labeled in the wiring diagram on page 17. That wiring diagram is worth the price of the manual alone. Aftermarket diagrams often swap pinouts. This one is from the factory.

One more thing: This is not a reprint. It’s the original scanned PDF from Diesel Performance Products. You can zoom in on the wiring colors and the torque specs without blur. Automotive Industry Overview might give you general context, but for the FASS install, stick to the OEM manual. If you’re also working on other diesel systems, check the Drogobych Crane КТА-16, КТА-25, КТА-28 2004 Installation Manual for crane hydraulic specs, or the Hyundai Seasall D170 & D150 Installation Manual for marine engine fuel lines. The Hella LEDay Flex Installation Manual – 48 Pages of Factory Specs covers lighting electrical, but that’s a different circuit.

19 pages. That’s all it takes to save a $2,500 fuel system install from going sideways. Automotive Industry Overview can teach you theory, but this manual teaches you the exact steps for one specific system. Access the Factory Manual and keep it on your tablet next to the lift.

Frequently Asked Questions

Does this manual cover the FASS 150/95-1007 only, or both models?

Both. The manual is for the 150/95-1007 and the 150/150-1007. The difference is the pump flow rating, but the installation procedure is identical.

Are torque values included for the mounting bolts?

Yes. The mounting bracket bolts and the filter cap torque are specified. They are in foot-pounds. Do not guess, because overtightening the filter cap cracks the housing.

What kind of warranty information is in the manual?

Pages 2 and 14 cover the warranty terms, the registration process, and the dealer support steps. Diesel Performance Products requires the original registration form and a copy of the purchase receipt within 30 days. The manual also includes the troubleshooting guide that dealers use—if you follow it, you can often solve a no-start issue yourself instead of waiting for a callback.

Can I use this manual for a 2006 Ford 6.0L Powerstroke?

If the truck is equipped with a FASS system that matches the model numbers, yes. The manual does not include vehicle-specific wiring adapters—those come separately—but the pump wiring and fuel line routing are standard. Check the inlet and outlet orientation on page 3 to verify compatibility.

This is the manual you want on the bench, not a generic diagram. Access the Factory Manual.

• Drogobych Crane КТА-16, КТА-25, КТА-28 2004 Installation Manual
• Hyundai Seasall D170 & D150 Installation Manual
• Hella LEDay Flex Installation Manual – 48 Pages of Factory Specs