How-To Install A FS-2500 Oil Bypass Filtration System On A 2007 Dodge 5.9L Diesel

The FS-2500 is a bypass filtration system specifically designed for diesel engines. Diesel engines generate a lot of soot that grinds away the moving parts of your engine. Modern emission controlled engines with EGR and post-injection technology are even more serious offenders when it comes to oil contamination.

Every engine needs a full-flow filter, but they have limitations. Because of the high volume of oil they must process, full-flow filters cannot be too restrictive or they would risk starving the engine of oil. The most efficient standard filter will remove particles down to about 25 microns. According to the Society of Automotive Engineers (Paper 881825) and a number of major diesel engine manufacturers, particles in the 4 – 7 micron range are responsible for up to 88% of engine wear. The FS-2500 is specifically designed to remove the damaging particles in this range which are NOT removed by your factory oil filter.

Instead of filtering your oil full flow, a bypass filter diverts a smaller percentage of an engine’s normal flow for finer filtration. The FS-2500 removes 99.63% of particles 2.78 microns and larger from the oil. No other bypass filter on the market can make that claim. The FS-2500 also removes water from condensation which causes acid buildup. Anyone who has ever disassembled a diesel engine knows what a dirty job it can be. By removing water and carbon particles, the FS-2500 will prevent the formation of this harmful sludge. Additionally, the life of the oil’s additive package will be significantly extended.

The filter element inside The FS-2500 should be changed every 10,000 miles. Oil analysis will determine the best oil change interval for your particular engine and usage patterns. Our average customer will perform a complete oil change every 25,000 to 30,000 miles. The FS-2500 will pay for itself in oil changes alone, especially for those who have chosen to make the investment in synthetic oil. Do the math – when you factor in the time, hassle, and cost of oil changes, extended engine life, environmental costs of oil production and disposal, the FS-2500 just makes sense!

Save your engine! The average oil film thickness between loaded components on an engine is in the range of 0.5 to 20 microns – imagine what a 5 micron piece of grit does when it gets jammed between a piston and cylinder wall with three microns of clearance and pressure that can exceed 500,000 PSI!

If you have installed a Power Chip, you’re dumping much more soot into your engine and increasing the load at the same time – especially when you see that black smoke rolling! Taking into consideration the soot and extra loads on the engine, you can’t afford NOT to install the FS-2500! Better lubrication means more power too.

The following installation is for a 2007 Dodge 5.9L. Each kit is custom built for your engine/chassis, with complete step-by-step installation instructions and color photos. Everything needed to perform the installation such as lines, fittings, brackets, and bolts are included. Most kits have a choice of standard rubber lines or an upgrade to stainless steel braided lines. Because of their exceptional durability and security, not to mention beauty, we recommend the stainless lines.

Will using the FS2500 affect my warranty?

Properly using the FS-2500 will result in oil quality far exceeding manufacturer requirements. The emphasis of OE requirements is on oil condition, not drain intervals. Your retained analysis records are evidence. Installing a bypass filter or other vehicle accessories will not void your warranty.

What comes in the box?

• (2) #4JIC to ¼” pipe
• (1) 1/4″ pipe 90 degree
• (1) Sample port
• (1) Sample probe
• (1) 1/4″ pipe plug
• (2) 3/8″ mounting bolt
• (2) 3/8″ lock washer
• (1) #4JIC to 1/8″ pipe
• (1) #4JIC to 1/8″ pipe 90 degree
• (1) Swivel cap
• (1) Bracket
• (3) Metric bolts
• (3) Metric lock washers
• (8) Zip ties
• (1) -5 Pressure hose, 27″ w/90 degree
• (1) -5 Return hose, 14″ w/90 degree

(A separate kit is available if you prefer to mount the unit on your frame rail. The Dodge is the only pickup with an under hood mount option. Some restrictions apply)

Installation Steps

Step 1: Position fittings and ports as shown in photo

Step 2: Remove the bolt and move the wiring harness off of the mounting pad location. The wiring harness will wrap underneath the bracket when completed. Install the bracket (Item #11 ) in the location shown above. Bolt the bracket to the mounting pad using the metric bolts (PN#B-4 ) (Item #12 ) and metric lock washers (PN#L-2 ) (Item #13). Torque the bolts to 30-35 lb. ft.

Step 3: Using the supplied 3/8″ bolts (Item #6) and lock washers (Item #7) bolt the FS-2500 to the bracket. Torque the bolts to 35-40 lb. ft.

Step 4: Oil Pressure: Remove the 1/8″ pipe fitting and install the #4JIC to 1/8″ pipe fitting provided in kit (Item #8). Connect the 27″ pressure hose to this fitting. Connect the 90 degree end of the hose to the IN port on the FS-2500.

Step 5: Oil Return: Remove the old oil fill cap. Remove the o-ring from the cap and install on the new aluminum swivel cap (Item #10). Install the #4JIC to 1/8″ 90 degree fitting into the cap (Item #9) . Reinstall swivel cap on the engine. Connect the 14″ hose to this fitting. Connect the 90 degree end to the OUT port on the FS-2500.

Step 6: Hose Routing: Secure hoses with included zip ties.

Step 7: Start your engine and check for leaks around all fittings.

Tags: Diesel, Dodge, Engine, Fuel

Category: How-To