Fuel system install 97 f250 - Ford Powerstroke Diesel Forum

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post #1 of 32 Old 03-24-2014, 05:47 AM Thread Starter
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Fuel system install 97 f250

Anyone give any tips on installing fuel system on a Obs. Main question is suction line and routing it to the motor. Truck allready has a regulator setup

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post #2 of 32 Old 03-24-2014, 07:26 AM
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In most cases the 3/8" steel line on the frame rail is sufficient to supply the engine. Is that line no longer there?

+ Matt +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, intercooler
-Irate: T-4 kit, IC pipes, 3" Irate Plenums, BASB Turbo
-Stage II trans.
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, ADRENALINE PUMP
-twin on-board air w/ 10 gal. tank

-Oh, and a 2015 F350 6.7L DRW 4x4

Re-pinning '97 Cali PCM to Federal
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post #3 of 32 Old 03-24-2014, 08:09 AM Thread Starter
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I can look an see i know its not recomended but this guy has a fass and is dead set on it so im trying get an idea on installing it

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post #4 of 32 Old 03-24-2014, 08:26 AM
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Yeah, seen your other thread. Ok, study this diagram and in particular the "To Engine" and "From Engine" these are the points of the selector switch that are rubber lines and where you'll make your hook-up.



The Larger of the two (3/8" line) is the feed so that is what is going to hook up to the "T" (inlet) side of the FASS system. The hard line up the rail will need to be connected to "E" (oulet) of the pump. No the tricky thing is the "R" for the return line. I would call FASS support and confirm this but you are going to want to plug that port and just use the engines normal return set-up. The Super Duty truck dead-head their fuel system into the heads with no return so this kit is using this alternate setup to make a SD a return setup (notice all the "engine lock-up" warnings in the install manual. Once you get air into a SD fuel line you're pretty f*cked. Mount near the pump near the tank selector and wire it up as described in the manual. [In the manual they go in detail about how to use teflon tape. THIS INFORMATION IS WRONG!!! Wrap the tape in the opposite direction!] And one more thing to note, add a "loss-less" ball valve to both the inlet and outlet of the pump housing. this will allow you to close the valves and remove the filters without loosing any more fuel then what is already in the filter during a filter swap.


+ Matt +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, intercooler
-Irate: T-4 kit, IC pipes, 3" Irate Plenums, BASB Turbo
-Stage II trans.
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, ADRENALINE PUMP
-twin on-board air w/ 10 gal. tank

-Oh, and a 2015 F350 6.7L DRW 4x4

Re-pinning '97 Cali PCM to Federal

Last edited by BigFuel; 03-24-2014 at 08:34 AM.
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post #5 of 32 Old 03-24-2014, 08:36 AM Thread Starter
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Ok his is been made to one tank. Rear only?

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post #6 of 32 Old 03-24-2014, 08:39 AM
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....your friends truck is a mess.....Is it at least a Bronco tank? The stock 19 gallon tank must be hell on travel distance.

Ok, does it still have the tank selector valve and he just doesn't use it?

+ Matt +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, intercooler
-Irate: T-4 kit, IC pipes, 3" Irate Plenums, BASB Turbo
-Stage II trans.
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, ADRENALINE PUMP
-twin on-board air w/ 10 gal. tank

-Oh, and a 2015 F350 6.7L DRW 4x4

Re-pinning '97 Cali PCM to Federal
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post #7 of 32 Old 03-24-2014, 08:42 AM Thread Starter
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Im not sure i believe its stock he dont drive often.

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post #8 of 32 Old 03-24-2014, 08:48 AM
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Ok, it's not uncommon for one of the tanks to leak and the owner just decides to run only the one tank. Look on the inner frame rail under the drivers seat and back a little. If the selector is still there please make the install as described above. Fuel tanks are pretty inexpensive these days (like $100) and hooking to the valve will allow your friend to later install a new tank and still use the FASS system without modification. If someone has hacked the system up to only run one tank then you are going to have to find the supply line from the tank (still should be the larger of the two lines, cut it, and install the FASS System as described above. Depending on the trucks shape it will surve you well to pull off the bed and do your probing from the top. It'll keep **** out of your eyes.

+ Matt +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, intercooler
-Irate: T-4 kit, IC pipes, 3" Irate Plenums, BASB Turbo
-Stage II trans.
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, ADRENALINE PUMP
-twin on-board air w/ 10 gal. tank

-Oh, and a 2015 F350 6.7L DRW 4x4

Re-pinning '97 Cali PCM to Federal
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post #9 of 32 Old 03-24-2014, 08:50 AM Thread Starter
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So i dont need to add a straw or something on the fass to attact to stock line?

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post #10 of 32 Old 03-24-2014, 08:51 AM
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Naw, shouldn't. Once you get the air out you should have zero issues with suction. Our trucks are designed this way.

+ Matt +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, intercooler
-Irate: T-4 kit, IC pipes, 3" Irate Plenums, BASB Turbo
-Stage II trans.
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, ADRENALINE PUMP
-twin on-board air w/ 10 gal. tank

-Oh, and a 2015 F350 6.7L DRW 4x4

Re-pinning '97 Cali PCM to Federal
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