User Manual Q&AAnswer
Mar 11, 2025 - 01:35 AM
Step 1: Locate the lower factory fuel filter assembly on the fuel tank. If your truck is a short bed, remove the three factory clips and the rock guard. Unplug the factory water-in-fuel sensor connector from the sensor. Open the yellow drain valve and drain the filter contents into a drain bucket. Loosen the 5 mounting bolts and remove the factory fuel filter.
Step 2: Remove the factory water-in-fuel sensor from the factory lower cover by twisting it out of the lock and pulling it out. Remove the pink sealing o-ring from the top of the factory fuel filter and the large sealing o-ring around the base of the lower housing.
Step 3: Clean all dirt and debris off the factory water-in-fuel sensor. Apply Vaseline or assembly grease on the o-rings and install them into the HSM fuel plate assembly. Twist the sensor into the lock position against the drain with the plug facing the arrows on the plate until it stops. Make sure the sensor is pushed into the plate all the way. Install the pink sealing o-ring onto the top of the "in" fitting and the large sealing o-ring into the groove around the base of the HSM fuel plate assembly.
Step 4: Install the HSM fuel plate assembly into the factory upper filter housing assembly. The tube must slide up into the fuel port inside the factory housing for correct installation. Install the five 6mm flange bolts by hand, ensuring they start straight and easily. Torque the bolts to 44in lbs. Do not overtighten to avoid damaging the factory filter housing.
Step 5: For long bed or aftermarket fuel tank filter housing and fuel line installation, install the HSM fuel filter block, two -8an fittings, mounting plate, four 3/8 button head allen bolts, and a 14mm flange lock nut. Lube the sealing o-rings on the -8an fittings and tighten them into the fuel filter housing. Install the fuel filter housing onto the mounting plate and secure it to the front driver side factory bed bolt using a 14mm locking flange nut and fender washer.
For short bed filter, filter housing bracket, and fuel line installation, install the HSM fuel filter block, two -8an fittings, mounting plates, and four 3/8 button head allen bolts. Lube the sealing o-rings on the -8an fittings and tighten them into the fuel filter housing. Install the fuel filter housing onto the mounting plate and secure it to the upper frame cross member using four 1/4x3" grade 8 bolts, flat washers, and 1/4 nyloc nuts.
Step 6: Route and install the provided fuel hoses to the appropriate fittings on the HSM fuel plate assembly and the remote fuel filter housing assembly. Ensure the hoses are routed correctly and tighten the fittings. Zip tie the hoses together to prevent rubbing on sharp edges.
Step 7: Install the provided CAT filter onto the housing, ensuring the provided o-ring is installed on the filter post. Hand tighten the fuel filter.
Step 8: For short bed trucks only, trim the splash/rock guard to fit around the filter lines and re-install it with the factory clips.
Step 9: Turn the key to the run position for 30 seconds to prime the system. Do not start the engine. Repeat this process until the system is primed, which may take 4-5 key cycles. Start the engine and check for proper function of the system.
Please note that it is important to thoroughly read and understand each step before attempting installation. If you are unsure, it is recommended to take the kit to a certified technician for installation.
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