Installation Manual v1.0: High Performance Fuel System Stage 1 Ford 6.0L Power Stroke. Please read all instructions before installation.

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1 FS0306S1-INST Installation Manual v1.0: High Performance Fuel System Stage 1 Ford 6.0L Power Stroke Please read all instructions before installation. Thank you for purchasing the ATS High Performance Fuel System for the Ford 6.0L Power Stroke. This manual is to assist you with your installation of the system. If you are installing this system for a customer, please pass this manual on to your customer for future reference. This installation, while not complicated, is time consuming. Some steps can be difficult due to the position of some components in the engine compartment. Please read through all of the instructions, and if you are not comfortable with the install, have a qualified technician do it. Below are photos of the fuel filter housing; use them for identifying the stock lines that this procedure will replace. Stock Fuel Return Line Stock Fuel Supply Line Stock Drivers Side Cylinder Supply Line

2 Stock Passenger Side Cylinder Supply Line 1. Begin by disconnecting the negative terminals of both batteries. 2. Remove both intercooler pipes. 3. Remove the air box assembly. 4. Remove the radiator support brackets. 5. Remove the four pin-type retainers and pull back the sight shield. With the sight shield pulled back, remove the three pin-type retainers and the two wiring retainers and position the harness rearward out of the way. 4 Pin Type Retainers Radiator Support Brackets 6. Remove the upper shroud retainers. 7. Drain coolant and disconnect the upper radiator hose and the radiator overflow hose. 8. Move the radiator forward. 9. Pull up on the shroud evenly, and remove the shroud from the radiator. NOTE: When installing the shroud, make sure that the aligning tabs are installed correctly in the slots. To install, reverse the removal procedure. 10. Remove the serpentine belt. 11. Remove the alternator. 12. Remove the fuel line that runs from the fuel filter housing to the front of the passenger side cylinder head. There is a fuel line attaching bolt directly below the intake throttle body, be sure to remove this first, then remove the banjo fitting. 2

3 Fuel Line Attaching Bolt Banjo Fitting 13. Remove fitting that is in the fuel filter housing where the fuel line was just removed. 14. Install 90 fitting A into the fuel filter housing and thread in as far as possible, then back-off one full turn (this prevents the fitting from bottoming out) with the bend in a horizontal orientation towards the passenger side of the engine. DO NOT fully tighten the locknut at this time. 15. Install 90 fitting A into the front of the cylinder head and thread in as far as possible resulting in an upward orientation. DO NOT fully tighten the locknut at this time. 16. Attach the supplied 20-5 braided line to fitting at the fuel filter housing and to the cylinder head fitting. 17. Route the supplied braided line from the fuel filter housing to the cylinder head so that the fuel line is away from moving parts and will not be pinched by the alternator. Installed Passenger Side Fuel Line Front view, passenger side line to cylinder head. 3

4 Top view, alternator removed. Rear view, routed under alternator to fuel filter housing. 18. After the braided line is properly routed, tighten the locknuts on both 90 fittings and tighten both braided hose ends. Driver s side fuel filter fitting. Note: Fuel line runs down behind thermostat housing, route braided line similarly. Driver s side banjo bolt. 19. Remove the fuel line that runs from the fuel filter housing to the front of the driver side cylinder head fitting. 20. Remove the fitting that is in the fuel filter housing at the location that the fuel line was just removed. 4

5 21. Install 90º fitting A into the fuel filter housing and thread in as far as possible with the bend pointing down, then back-off one full turn (this prevents the fitting from bottoming out). DO NOT fully tighten the locknut at this time. 22. Install 90º fitting A into the front of the cylinder head and thread in as far as possible resulting in an upward orientation for the bend. DO NOT fully tighten the locknut at this time. 23. Attach the supplied 9-5 braided line to the 90 fitting at the fuel filter housing and to the cylinder head fitting. See figure on next page for line routing arrangement. Installed Driver Side Fuel Line Driver s side view, from front of cylinder head to fuel filter housing. 9 line has a slight bend back towards filter housing. Stock fuel supply and return lines are removed for ease of viewing. 24. After the braided line is properly routed, tighten the locknuts on A fittings and tighten braided hose ends. Remember not to bottom out the fittings on the fuel filter housing. 25. Double check that all fittings are tight before reassembly. 26. Reinstall the alternator; be sure that the fuel line does not get pinched. 27. Reinstall the serpentine belt. 28. Reinstall the fan shroud assembly. Fan shroud to radiator attaching bolts should be torqued to 80 inch-lbs. Radiator support retainer hold down bolts should be torqued to 9 ft-lbs. 29. Reinstall the upper radiator hose and the radiator overflow hose. ENSURE TO TOP OFF ANTIFREEZE. 30. If you have purchased the stage 2 or 3 fuel kits then proceed to those instructions at this time. 31. Reinstall the air box. 32. Reinstall the intercooler pipes. 5

6 33. Reconnect the negative battery cables. 34. Run vehicle and the recheck for any fuel leaks. We strive to make our instructions as clear and complete as possible. To achieve this, our instructions are under constant construction. We encourage you to visit our Technical Support Website ( to check for the most up-todate manuals and diagrams as well as other information. If you have any suggestions as to how we can improve this installation manual, let us know at Thank you for purchasing the ATS High Performance Fuel System. Call or check our website for other products that ATS has developed for the 6.0L Power Stroke including E-Power Tuners, Head Studs and Fire Rings, fuel injectors, Aurora Turbochargers, Five Star Viskus Drive Torque Converter, Heavy Duty Transmission, Torque Pro Propane Injection, and Stainless Steel Exhaust. If you have any problems with this install, please call or our Technical Service Department, 8:00am to 5:30pm Mountain Standard Time, Monday through Friday. Contact Information Toll Free: Local: Fax: Website: 6

7 ATS Diesel Performance Limited Warranty Statement ATS Diesel Performance warrants the original purchaser that any parts purchased shall be free from defects in material and workmanship. ATS Diesel Performance is the warrantor of this product, in the event this produce is purchased form a distributor or retailer other that ATS Diesel Performance the customer must contact ATS Diesel Performance for any warranty concerns, not the purchasing dealer. A defect is defined as a condition that would render the product inoperable. This warranty does not cover deteriorating of plating, paint or any other coating. ATS liability is limited to the repair or replacement, at ATS s option, of any warrantable product returned prepaid with a complete service history and proof of purchase to the factory. A valid proof of purchase is a dated bill of sale. Repaired or replaced, product will be returned to the customer, freight collect on a like-for-like part number basis. Accepted warranty units, which have been replaced, become the sole property of ATS. A Return Product Authorization number obtained in advanced from an ATS customer service representative must accompany products returned for warranty determination. ATS will be the final authority on all warranty decisions. This warranty shall not apply to any unit which has been improperly stored or installed, subjected to misapplication, improper operating conditions, accidents, or neglect; or which has been improperly repaired, altered or otherwise mistreated by the owner or his agent. This warranty shall terminate at the end of 12 months in service with the original user. Labor cost incurred by the removal and replacement of an ATS product, while performing warranty work, will be the responsibility of the vehicle owner; in no case does the obligation of ATS Diesel Performance exceed the original purchase price of the product as indicated on the original bill of sale. Except as set forth in this warranty, ATS disclaims any implied warranty, including implied warranties of merchantability and fitness for a particular purpose. ATS also disclaims any liability for incidental or consequential damages including, but not limited to, repair labor, rental vehicles, hotel costs or any other inconvenience costs. This warranty is in lieu of all warranties or guarantees, either expressed or implied, and shall not extend to any customer or to any person other than the original purchaser residing within the boundaries of the continental US or Canada ATSdiesel.com 7

This kit may void factory warranty please check with manufacturer.

This kit may void factory warranty please check with manufacturer. Mfg Company TM Thank you for purchasing a Sinister Manufacturing Company EGR delete kit. Precision manufactured using aircraft quality 304 stainless steel and billet aluminum; this EGR kit is designed