AFe Power Dfs780 User manual

advanced FLOW engineering

Instruction Manual P/N: 42-14012

Make: GM Model: Diesel Trucks Year: 2001-2010 Engine: V8-6.6L (td) Duramax

Fuel Pressure: 8-10 PSI (Boost Operated) Supported Horsepower: 2000+

Label Qty. Description Part Number

A 1 Fuel Manifold Assembly 05-60565

B 1 Filter, Fuel 44-FF019

C 1 Bowl, Water Separator 05-60487

D 1 Bracket, Frame, Carbon Steel 05-60655

E 1 Bolt, M8 x 1.25 x 25mm 03-50442

F 1 Washer, Flat: 24mm ODxM8 ID 03-50065

G 1 Nut, Hex Nylon Lock: M8 x 1.25 03-50244

H 4 Screw, Socket Head Cap M6x1.0x50mm 03-50443

I 4 Washer, M6 (Fiber) 03-50457

J 4 Washer, M6 03-50444

K 4 Nut, Flanged Nyloc: M6 03-50445

L 2 Fitting: 3/8" NPT to AN -8 (Black) 05-60685

M 1 Harness, Stand Alone Relay 05-60551

N 1 Connector, Add-A-Harness 05-60583

O 1 Hose, Fuel Return 05-60689

P 12 Ties, Nylon Cable, 12" 05-60167

Q 1 Harness, Power 05-60523

R 1 Hose, Fuel Inlet 05-60673

S 1 Hose, Fuel Outlet 05-60681

T 1 Jumper, Priming 05-70004

Note: Legal in California for use on race vehicles only. The use of this device on vehicles used on public streets or

highways is strictly prohibited in California and others states that have adopted California emission regulations.

• Please read the entire instruction manual before proceeding.

• Ensure all components listed are present.

• Ensure you have all necessary tools before proceeding.

• Do not attempt to work on your vehicle when the engine is hot.

• Disconnect the negative battery terminal before proceeding.

• Retain factory parts for future use.

Page 2

Page 3

OAB

MNP

Step 1: Looking at the driver’s side of the truck, on the inside of the frame rail, you will see two hard

lines. These are the fuel supply and return lines for the engine. They are held in place by plastic

retainers that are bolted to the frame (shown above).

Step 2: Locate the retainer that is below the driver’s side door and is two retainers away from the fuel

cooler.

Step 3: Loosen all the stock fuel line retainers from the frame using a 13mm socket/wrench while leaving

the fuel lines in their retainers.

REMOVAL

Page 4

Figure 1

2 3

Refer to Figure 1 for Steps 1-3

Step 4: Gently pull the fuel lines off of the frame rail. Please be careful not to bend or kink the fuel lines.

Step 5: Place the supplied bracket between the frame and the stock fuel line retainer located in Step 2.

Step 6: While making sure the bracket is sitting on the bottom of the frame, tighten the stock fuel line

retainer.

Step 7: Tighten all the fuel line retainers.

NOTE: If the fuel line retainers are not there please use the supplied hardware to attach the

bracket to the frame.

INSTALL

Page 5

Figure 2

Refer to Figure 2 for Steps 4-7

NOTE: This is what the bracket looks like when installed correctly.

Page 6

Rear of truck

INSTALL

Figure 3

Step 8: Connect the bracket to the manifold using the four (4) supplied M6x1.0 x 50mm bolts,

M6 washers, felt washers and M6 ﬂange nuts. The felt washers go between the pump and the

bracket.

Step 9: Tighten the manifold to the bracket.

INSTALL

Page 7

Refer to Figure 4 for Steps 8-9

Figure 4

Refer to Figure 5 for Step 10

Step 10: Turn sight glass to the desired angle and using a 1-1/4" wrench, tighten the center nut under

the DFS780 manifold.

NOTE: The pump should look like the picture above.

Figure 5

INSTALL

Page 8

Page 9

Refer to Figure 6 for Step 11

Step 11: Using a light oil, lube the gasket on the fuel ﬁlter before installation. Attach the supplied water

separator bowl onto the supplied fuel ﬁlter.

Figure 6

INSTALL

Figure 7

Refer to Figure 7 for Step 12

Step 12: Apply Teﬂon tape with (PTFE) or Teﬂon paste with (PTFE) to the 2 x 3/8" NPT to -8 AN ﬁttings.

NOTE: Only apply Teﬂon to the NPT side of the ﬁtting.

INSTALL

Page 10

“AN ﬁtting” side

“NPT” side

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