FASS Diesel Fuel Systems offer a comprehensive approach to fuel conditioning and protection for diesel engines. Originally designed for commercial trucks, these systems have become a popular upgrade for both Class 8 vehicles and pickup trucks, as well as diesel-powered equipment like tractors and generators. The systems combine air and vapor separation, advanced filtration down to 2 microns, and consistent fuel pressure to improve engine performance and extend the life of injection systems. Installation ranges from relatively simple drop-in replacements to more involved setups requiring drilling, and maintenance is primarily limited to routine filter changes.
System Overview and Benefits
FASS Diesel Fuel Systems are designed to address common issues associated with diesel fuel quality and delivery. The documentation highlights three key functions integrated into a single unit: air and vapor separation, advanced filtration, and consistent fuel pressure. Entrained air in diesel fuel can lead to pressure drops, cavitation, hard starts, and premature injector wear. FASS systems remove this air, ensuring a consistent fuel supply.
The advanced filtration capabilities of FASS systems are a significant improvement over stock filters, removing over 99% of water and filtering down to 2 microns absolute. This is particularly important as water contamination can cause significant damage to the fuel injection system. The FASS Extreme Water Separator provides an additional layer of protection against extreme water contamination, preventing contaminated fuel from reaching the engine.
Maintaining consistent lift pump pressure reduces strain on the injection system and ensures stable fuel delivery, even under heavy load. The documentation states that installing a FASS Diesel Fuel System can potentially triple the life of an injection system.
Installation Procedures
FASS offers a range of systems designed to accommodate different installation complexities and user skill levels. The documentation categorizes installations into three primary types:
- Drop-In Series: These systems are designed for quick and easy installation, typically taking between 1 and 3 hours. They utilize factory locations and OEM fuel lines, eliminating the need for cutting or drilling.
- No-Drop Systems (with sump): These installations are more involved but still manageable for experienced DIYers or professional shops. They require drilling a single hole for the sump.
- Full Titanium Signature Series: These systems are ideal for performance builds or as a long-term upgrade. Professional installation is recommended to ensure optimal results.
Detailed installation instructions are provided with each kit. Additionally, a Missouri-based service team is available to provide step-by-step guidance during the installation process.
Maintenance Requirements
FASS Fuel Systems are designed for long-term reliability and require minimal maintenance. The primary maintenance task is routine filter changes. Regular filter changes ensure the system continues to deliver clean, air-free fuel, preventing potential issues such as power loss, hard starts, or injector wear.
Beyond filter changes, the documentation recommends inspecting fittings and lines for leaks during installation and periodically thereafter. It is also advisable to inspect the wiring and mounting hardware to ensure everything remains secure. The systems are designed to operate for hundreds of thousands of miles with minimal attention.
Fuel Economy and Warranty Considerations
The documentation does not provide conclusive evidence regarding improvements in fuel economy resulting from FASS system installation. However, the benefits of cleaner fuel and consistent pressure could potentially contribute to optimized engine performance and, consequently, improved fuel efficiency.
Regarding warranty concerns, installing a FASS Diesel Fuel System does not, in itself, void the factory warranty. The Magnuson-Moss Warranty Act protects consumers by preventing manufacturers from voiding warranties solely due to the installation of aftermarket parts, unless those parts can be directly proven to have caused a failure. Some dealerships and performance shops even recommend FASS systems, recognizing that they exceed OEM filtration requirements and improve the longevity of expensive injection system components.
System Selection
Choosing the appropriate FASS system depends on specific needs and application. The documentation does not provide detailed guidance on sizing, but implies that the choice depends on factors such as vehicle type, engine modifications, and intended use. The available series include:
- Titanium Signature Series
- Competition Series
- Industrial Series
- Titanium Series
- Signature Series Adjustable Fuel Pump
- Adjustable Series
- DDRP Dodge DRP Series
- Duramax DMax Series
- Drop-In Series
- FASS Pump Accessories
Addressing Water Contamination
Diesel fuel is susceptible to water contamination, which can lead to corrosion, fuel injector damage, and reduced engine performance. FASS systems address this issue through advanced filtration and the inclusion of a water separator. The FASS Extreme Water Separator acts as a fail-safe mechanism, preventing severely water-contaminated fuel from reaching the engine. This is particularly important in situations where a vehicle is inadvertently filled with fuel containing a significant amount of water.
Conclusion
FASS Diesel Fuel Systems provide a comprehensive solution for improving the quality and delivery of fuel to diesel engines. By combining air and vapor separation, advanced filtration, and consistent fuel pressure, these systems offer benefits such as extended injection system life, improved engine performance, and protection against water contamination. Installation options range from simple drop-in replacements to more complex setups, and maintenance is primarily limited to routine filter changes. The systems are designed for long-term reliability and are backed by a warranty-friendly design, making them a popular upgrade for both commercial and consumer diesel applications.