After that test passed and it was cranking normally I feel pretty good about this fix. I just wanted to take a few minutes to post up all my findings and put some closure to this thread.

I temp hooked up my tail lights and took it for a test drive and it did great. I filled the tank up and the gauge works as it should. I had read one of these installs where the guy puts the bed back on before he filled the tank up and hand to remove again to fix an issue (float arm on the sending unit was hitting a hose).

Now all that's left is to put the bed back on.

I know this has been mostly me posting in this thread but if anyone has any questions I'll answer if I can. I feel like I've learned a lot going through this and hope to be able to use this in the future. I've put together a folder that stays in the truck as well as a little box of test fittings, hoses, canister, etc that would allow me test things if I ever needed to.

 

Very nice write up and pics. Excellent methodical approach to upgrading your low side fuel system.

The pre-pump filter strainer is an excellent idea. I wish more guys would install one to prevent issues with their aftermarket fuel pump.

Did you install additional fuel filtration between the Fass fuel pump and the CP3 injection pump.?

If not, I would strongly recommend installing an additional fuel filter between the stock fuel filter in the stock cannister and the Cp3.
This will protect your fuel injectors.

The Glacier diesel intake air horn mounted fuel filter is excellent.

Also, I recommend that you install a low side fuel pressure gauge.
This will monitor your Fass fuel pump plus your fuel filters.

I have a Walbro external fuel pump, pre-pump filter/strainer, stock fuel filter in the stock cannister plus the Glacier air horn mounted fuel filter plus an Autometer 30Psi fuel pressure gauge, all 3/8" line.

It cost me a ton of dollars but no issues since installed 9 years ago.
It was all worth it.

 

I didn't add anything between the FASS pump and the CP3. I saw where most installs route the FASS hose directly to the CP3 and basically omit the stock fuel filter canister. I followed suit thinking that the filter that's mounted to the FASS gets debris down to 3 micron and the filters that go in the OEM canister only filter down to 7 micron. I hate that I have now also omitted the water in fuel sensor. (although I did find a fleetguard filter with F/W sensor but I'm not sure if its recommended for use in my ap) http://www.glacierdieselpower.com/pr...?pf_id=FS19596

Gauges both high and low pressure are now on my wish list once I recover from the pump expenses.

 

BTW, good to know someone was actually reading this.

 

I don't recommend bypassing the stock fuel filter cannister and WIF sensor. I don't see a reason to.
I would reconnect it and at a minimum install a Baldwin 5 micron drop in fuel filter into it if you don't install additional fuel filtration.

As for the FASS fuel filter mounted on the FASS fuel pump, I wouldn't trust their filtration claims for it.



It's labeled for filtration and water separation.
We need member AH64ID to comment on that FASS filter.


I guarantee that many folks are reading your excellent thread!

 

I'll see what I would have to do to go back and include the factory filter system. I know some folks would have an issue with 'restrictive' factory fuel line sizes but since everything I have is stock I'm not that concerned.

I think I would have to source a push lock banjo fitting to hook the 1/2" line to the back of the stock canister.

 

Thank you for you time and dedication to help other members. Your thread is very good and it shows to many of us how to fix our same issue. Impressed by your systematic approach, that's how you do a good job.

 

Thanks for the kind words Zman. 😀
Truck has been running flawlessly for the past few weeks. So far so good!

 

BTW, another good piece of info here if it's not posted elsewhere on the forum...

I weighed my bed when I was putting it back on. 187 kg = 412.26#.
8' bed, with Line-X at 1/8-3/16" thick. No tailgate, lights, toolbox, etc.