DF-100, DF-165, & DF-200 INSTALLATION MANUAL DURAMAX DIESEL POWERED Chevy & GMC TRUCKS 2001 thru 2009 High Performance Fuel System With New Quick Connect Components! PLEASE READ THE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION PureFlow AirDog 705 MAUSOLEUM ROAD SHELBYVILLE, IN 46176 1-877-421-3187 www.pureflowairdog.
Approved for Sale and Use in California by CARB! (Limited Edition Model Pictured) PRESET OR ADJUSTABLE PRESSURE REGULATOR SMALL RETURN LINE FOR AIR, VAPOR AND FOAM PROTECTIVE WIRE SCREEN IN PRE-FILTER NIPPLE DEMAND FLOW SERIES FLOWS ONLY THE AMOUNT OF FUEL THE ENGINE DEMANDS SMALL and COMPACT 7” Long X 3.
OVERVIEW Welcome to PureFlow® AirDog®II Fuel Air Separation, Filtration and Delivery System for the Diesel Engine The AirDog®II Fuel Preporator®, the Original Fuel Air Separation System, is a premium fuel pump and complete filtration system for the DuraMax Diesel Engine. The system removes water, particulates and entrained air from the fuel. The entrained air separated from the fuel is returned to the tank through a small return line.
QUICK CONNECT COMPONENT OVERVIEW Provided in this kit are two different OE style quick connection systems. These systems work together to allow for a quick, clean, and professional install. Jiffy Tite Quick Connect System Jiffy Tite’s patented quick connect system is used for the connections at the AirDog® . The images below show the flared formation of the Jiffy Tite System. Simply insert the male end form into the fitting and push firmly until you hear it “click” into place.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel Table of Contents Section 1 TABLE OF CONTENTS Section 1……………………………….……..……………..Table of Contents Section 2…………………………………....Installation & Safety Guidelines Section 3……………………………….………………………..…….Parts List INSTALLATION PROCEDURES Section 4…………………….………….……AirDog®II & Mounting Brackets Fuel Lines Section 5 A……………………………….……..…..….…AirDog®II to Engine Section 5 B……………………...……….…………….…Fuel Return to Tank Section 5 C……………………..……………..……....
PureFlow AirDog ® AirDog II Demand Flow Section 2 2001-2009 DuraMax Diesel Installation & Safety Guidelines AirDog® II The installation of your AirDog® II can be made relatively easy by following the steps outlined in this manual, and: 1. Inventory the package components completely. Notify PUREFLOW AIRDOG immediately of any parts missing or damaged. 2. Read the installation manual completely. Understand how the system operates and installation recommendations before beginning installation. 3.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel Parts List Section 3 AirDog®II Parts List 1 Installation Manual 1 AirDog®II 1 AirDog®II Mounting Bracket 201-1-0222 DF-100 DF-165 DF-200 001-3C-0004 Mounting Hardware Kit, 1 901-61-0102-PM-C 010-3C-0002PC 010-3C-0001PC 5E-2-010 5H-2-1-06/12 010-3C-0003-A-P 1 Frame Bracket Set 1 1 1 Wiring Harness Bundle of Plastic Ties Spacer 1 Suction Hose Assembly WAP110-8-8 1 Return Hose Assembly WAP112-8-6 1 Pressure Hose Assembly
ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel AirDog®II & Mounting Brackets Section 4 Installing the AirDog® II & Mounting Brackets on the Truck’s Frame! Figure 2 Figure 3 4-1. Assemble the AirDog II mounting bracket to the frame bracket. 4-2. Use the spacer block to clear lines and wiring harnesses on the frame. Adjust the assembly up or down on the frame bracket as necessary for clearance. Figure 4 Figure 5 Out to ENGINE 4-3.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2009 DuraMax Diesel AirDog® & Mounting Brackets Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame, cont’d! NOTE: The AirDogII installs easily and is well protected from road debris when mounted on the inside of the driver’s side frame. Driver’s Side Frame Rail. Figure 9 4-5. Figure 10 Clamp the frame between the AirDogII bracket assembly and the backing plate using the 3/8” x 4” bolts, lock washers, and nuts included in the kit.
PureFlow AirDog AirDog ® 2001-2009 DuraMax Diesel Fuel Lines Section 5A Installing the AirDog II Fuel Supply Line to the Engine To install the AirDog II fuel supply line to the engine you must first remove the (flexible) factory fuel line connecting the fuel tank to the frame mount steel fuel line. NOTE: The fuel tank connections are located behind the tank shield. It may be necessary to remove or bend the tank shield down to access the suction tube quick connect fitting.
PureFlow AirDog AirDog ® 2001-2009 DuraMax Diesel Fuel Lines Section 5A 5A-3. Attach, by pushing, the female 1/2” SAE J2044 quick connect end (Figure 16) of the “Pressure Hose Assembly” onto the factory male quick connect that was disconnected in step 5A-2 (Figure 15). You will hear a “click” when properly connected. Figure 16 5A-4.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel Fuel Lines Section 5B AirDog®II Air/Vapor Return Line! NOTE: The AirDog II Air/Vapor return line connects to the engine return line at the fuel cooler. 5B-1. Disconnect the fuel return line from the fuel cooler inlet tube. (Figure 20) 5B-2. Remove the original fuel cooler inlet tube from the fuel cooler. (Figure 20) Figure 19 Figure 20 5B-3.
AirDog®II Demand Flow 2001-2009 DuraMax Diesel Fuel Lines Section 5-B AirDog®II Fuel Return Line, cont’d 5B-6 Insert the Jiffy Tite male quick connect end (see Figure 23) of the “Return Hose Assembly” into the previously installed female Jiffy Tite fitting in the port marked “Tank”. The fitting will “click” when properly installed. Figure 23 5B-7. Any excess fuel hose can be addressed by routing the hose in a fashion to take up the extra length, or a section of the hose can be removed.
AirDog®II Demand Flow 2001-2009 DuraMax Diesel Fuel Lines Section 5-C Fuel Suction Line for AirDog® II 5C-1. Insert the male Jiffy Tite quick connect end (see figure 24) of the “Suction Hose Assembly” to the female Jiffy Tite fitting install in the “Fuel In” port during step 4-3 of this manual. A “click” will be heard when the fitting is properly connected. Figure 24 5C-2.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2009 DuraMax Diesel Fuel Lines Section 5-C Fuel Suction Line for AirDog® II Cont’d 5D-4. Route and attach the female ½” SAE J2044 end (Figure 27) of the “Suction Hose Assembly” to the male quick connect fitting addressed in step 5D-3. You will hear a “click” when properly connected. Figure 27 5D-5 Any excess fuel hose can be addressed by routing the house in a fashion to take up the extra length, or a section of the hose can be removed.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel Electrical Harness Section 6 The AirDog®II is equipped with a relay controlled wiring harness.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel Electrical Harness Section 6 Connecting the AirDog®II Relay Control 6-2. Remove the plastic housing (skirt) around the fuse box. On some models it may be necessary to remove the fender/cowl brace to allow access to the fuse box. 6-3. After accessing the fuse panel, use a test light or voltmeter to find a fuse terminal that is HOT only when the ignition is in the on position.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel Electrical Harness, cont’d Section 6 Connecting the power supply leads, cont’d 6-4B. Should you choose to connect the power supply leads directly to the battery, connect the RED (+) lead to the POSITIVE (+) post of the driver's side battery. Connect the BLACK (-) lead to the NEGATIVE (-) post of the same battery. Black (-) Red (+) Figure 36 6-5.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel Initial Startup Procedures Section 7 INITIAL START PROCEDURE The AirDog®II is a self priming system, however, to prevent potential damage and reduce the life expectancy of the system, it is recommended to pre-fill only the water separator with diesel fuel before initial startup. 7-1. Fill the water separator with diesel fuel. 7-2. Turn the starter key to the on/run position. 7-3.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel Fuel Filter & Water Separator Section 8 Filter Service Recommendations Plugging of either the fuel filter, the screen in the water separator nipple or the water separator itself will cause low fuel pressure and low blow to the engine. Should you experience low fuel pressure, first check the screen in the water separator nipple.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel AirDog®II Fuel Pump Section 9 Cleaning Debris from the Gerotor Assembly Step 1 Step 2 Remove the four (4) socket head cap crews that secure the gerotor cap. Step 3 Carefully remove the O-rings. you will need to re-use them. Step 4 Remove and clean the gerotor assembly. Be careful not to damage the gerotor. Step 5 Clean the inside of the gerotor pocket. Step 6 Replace the center gear.
PureFlow AirDog ® AirDog II Demand Flow 2001-2009 DuraMax Diesel Pressure Regulator Section 10 AirDog II DF-165 with Adjustable Pressure Regulator! The AirDog®II rises to a new level of excellence with an Adjustable Regulator machined from stainless steel with a double O-ring seal system and a soft seat piston.
PUREFLOW AIRDOG LIFETIME LIMITED EXPRESS WARRANTY FOR All PureFlow AirDog I, II and Raptor Systems IMPORTANT NOTICE TO ACTIVATE YOUR PURFLOW AIRDOG WARRANTY, YOU MUST COMPLETE AND MAIL YOUR WARRANTY CARD TO PUREFLOW AIRDOG WITH A COPY OF YOUR ORIGINAL SALES RECEIPT WITHIN 30 DAYS OF PURCHASE. FAILURE TO COMPLETE AND SUBMIT YOUR WARRANTY CARD WILL RESULT IN A WARRANTY PERIOD OF THE COVERED PRODUCE TO ONE (1) YEAR FROM THE DATE OF PURCHASE.
shall be in no way responsible for the open use and service of the PRODUCT and the BUYER hereby waives all rights other than those expressly written herein. This Warranty shall not be extended or varied except by a written instrument signed by SELLER and BUYER.
