FS0306S2-INST Installation Manual v1.1: High Performance Fuel System Stage 2 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 the instructions before starting work, and if you are not comfortable with the install, have a qualified technician do it. 1. Begin with Stage 1 instructions until directed to this manual. 2. Raise the pickup and support it with jack stands or hoist that are rated to safely support the weight. 3. Remove the retaining bolts that hold the exhaust manifolds to the driver s side turbo uppipe. Bolts can be stubborn to remove and may require replacement to complete procedure. Passenger side turbo up-pipe should not need removing; however, we recommend that you remove the down-pipe for easier installation. 4. Carefully move the up-pipe away from the cylinder head just enough to allow access to fuel plugs. Caution: DO NOT damage the up-pipe by moving too far. If at any point you feel that the up-pipe will not move away further and you cannot perform installation, then removal of the clamps at turbocharger turbine inlet and Exhaust Gas Recirculation (EGR) cooler inlet, and retaining bolts to up-pipe on passenger side will be required to finish installation. 5. Using a 6mm hex wrench, remove the plug from the rear of the cylinder head on both driver and passenger side. Caution: Fuel may leak from the plugs. D B C Rear Cylinder Head Parts
Driver s side rear cylinder head plug. Driver s side rear cylinder head plug (larger view). Dashed line shows approximate route of steel line from banjo fitting. 2
Locating Tabs Close up of cylinder head bolt before it s removal. Note the locating tabs; the hard line is routed between these two tabs (done in steps 6 and 7). Rear Driver Side Assembled Regulated Return Line (Banjo bolt and washers, Driver side hard line (B), Part D, and 35-4 line). This is the approximate distance for moving the up-piping, take care not to move it too far and damage the piping. 3
Passenger s side rear cylinder head plug Dashed line shows route of steel line from banjo fitting. Rear Passenger Side Assembled Regulated Return Line (Banjo bolt and washers, Passenger side hard line (C), Part D, and 30-4 line). 4
6. Route hard fuel line B to formerly plugged hole in the driver side rear cylinder head, direct it through the locating tabs on cylinder head (shown in photo on page 3), insert and tighten the banjo bolt with washers (torque banjo bolt to 28 ft-lbs). Keep line away from heat shields; make slight adjustments to the hard fuel line if necessary. Do not kink the line and ensure line is not in contact with any components. 7. Route hard fuel line C to formerly plugged hole in the passenger side rear cylinder head, direct it through the locating tabs on cylinder head (shown in photo on page 3), insert and tighten the banjo bolt with washers (torque banjo bolt to 28 ft-lbs). Keep line away from heat shields; make slight adjustments to the hard fuel line if necessary. Do not kink the line and ensure line is not in contact with any components. 8. Reinstall turbo up-pipe bolts and tighten at this time (torque up-pipe bolts to 20 ft-lbs). Reinstall clamps at turbocharger turbine inlet and EGR cooler inlet and reinstall downpipe if removed. 9. Lower the vehicle. 10. Remove the Fuel Injection Control Module (FICM) on the driver s side of the engine may ease installation. 11. Put D (45 degree fitting) on hard line B (from the back of the driver side cylinder head). 12. Install the 35-4 braided line into D, and tighten. 13. Route braided line toward back of Regulator Assembly as shown. 14. Reinstall the FICM if previously removed. 15. Put a second fitting D on hard line C (from the back of the passenger side cylinder head). 16. Install the 30-4 braided line into C, and tighten. 17. Route braided line toward front of Regulator Assembly as shown. Regulator Assembly E -4 line 35 30 F G H -6 line 5
Regulator Assembly mounted on Alternator. 18. Assemble Regulator with fittings E, F, G, and H and mounting plate as shown. 19. Remove the two passenger side Alternator attaching bolts and position Regulator Assembly atop Alternator. Do not mount Regulator Assembly at this time, you will want some play when you route the lines. 20. Attach the 35 braided line (from the back of the driver side cylinder head) to the 45 fitting F at the back of the regulator. Make sure the line is positioned properly before tightening. 21. Attach the 30 braided line (from the back of the passenger side cylinder head) to the 90 fitting H at the front of the regulator. Make sure the line is positioned properly before tightening. Stock Fuel Filter Housing Stock Fuel Return Line Stock Fuel Supply Line Stock Driver s Side Front Cylinder Head Supply Line. 6
22. Remove the stock fuel return line and fitting at the fuel filter housing. 23. Put the 90 fitting J and adapter fitting K on to the stock fuel return line that was just removed. Attach 29-6 braided line to fitting K, route across engine, and attach to 90 fitting G on bottom of Regulator Assembly. 24. Install I (plug with copper washer) in place of the fuel return line fitting on filter housing. 25. Tighten ALL connections at fuel return line and at Regulator Assembly. Pictures of Steps 23 and 24 J K -6 line Stock Fuel Return Line I Completed Stage 1 & 2 Fuel Filter Housing 7
26. Install Alternator attaching bolts and mount Regulator Assembly. 27. Assemble Tee as shown below, Teflon tape is recommended for the three hose barbs. Attach supplied 3/16 hose to nipple on Regulator Assembly. Route hose to Manifold Absolute Pressure (MAP) sensor line. Cut line and insert Tee Assembly. Attach hose from Regulator to Tee. Clamp all lines with supplied hose clamps. Tee assembly (exploded view). 3/16 line on front of Regulator Assembly. Tee Assembly spliced into MAP line. 8
28. If you have purchased the stage 3 fuel kit then proceed to those instructions at this time. 29. Reinstall the air box. 30. Reinstall the intercooler pipes. 31. Reconnect the negative battery cables. 32. Start the truck. Check for any fuel leaks. Using a fuel pressure gauge adjust pressure to 50 psi at idle. For more performance, pressure adjustment can be set up to 70 psi at idle.* To adjust pressure loosen locknut on regulator and turn clockwise to raise pressure and counter-clockwise to lower pressure. *The 70 psi setting will ensure maximum fuel supply from the stock pump to the cylinder heads under high demand conditions. The down side of this is more wear and tear on the stock pump due to constantly having to maintain the higher idle fuel pressure setting. An ATS Stage 3 kit (with an Aeromotive Marine Grade Extreme Duty Fuel Pump) will supply all fuel demand without needing an excessively high idle fuel pressure setting. 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 (http://www.atsdiesel.com/atswebsite/technical.asp) 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 Suggestions@ATSDiesel.com 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 problems with this install, please call or e-mail our Technical Service Department, 8:00am to 5:30pm Mountain Standard Time, Monday through Friday. Contact Information Toll Free: 800-949-6002 Local: 303-431-7973 Fax: 303-431-01135 Website: www.atsdiesel.com Email: info@atsdiesel.com 9
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. 2005 ATSdiesel.com 10