#23 INSTALLATION MANUAL DF-100 & DF-165 Adjustable Regulator 2011 FORD POWERSTROKE 6.7L DIESEL ENGINE High Performance Demand Flow Fuel System PLEASE READ THESE 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! ADJUSTABLE PRESSURE REGULATOR SMALL RETURN LINE FOR AIR, VAPOR AND FOAM DEMAND FLOW SERIES FLOWS ONLY THE AMOUNT OF FUEL THE ENGINE REQUIRES SMALL and COMPACT 7” Long X 3.
OVERVIEW Welcome to PureFlow Airdog’s 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 an all in one premium lift pump and complete filtration system for the 6.7L Ford PowerStroke Diesel. 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 return line.
QUICK CONNECT COMPONENT OVERVIEW Provided in this kit is an OE style quick connection system. This system works to allow a quick, clean, and professional install. SAE J2044 Quick Connect System The SAE J2044 quick connect system is the most commonly used system in the automotive industry. The images below show the formation of SAE J2044 connection. To connect the assemblies, simply insert the male end form into the mating female connector. Push firmly until you hear it “click” into place.
AirDog®II Ford PowerStroke 2011 6.7L Table of Contents Section 1 TABLE OF CONTENTS Section 1…………………………….…….….………......…Table of Contents Section 2………………………….........…Installation and 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……………………...……..……..AirDog®II Fuel Return to Tank Section 5 C……………………..……………….........
AirDog®II Ford PowerStroke 2011 6.7L Installation & Safety Guidelines Section 2 AirDog®II MODEL DF-100 & DF-165 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.
AirDog®II Demand Flow Ford PowerStroke 2011 6.
ILLUSTRATION OF COMPONENTS 8
AirDog®II Ford PowerStroke 2011 6.7L AirDog®II & Mounting Brackets Section 4 Installing the AirDog®II & Mounting Brackets on the Truck’s Frame. 4-1. Install a 1/2” male J2004 quick connect x 3/8” NPTF (08J2044) into the “ENGINE” port. Figure 2 Then install the 3/8” NPT x -8 JIC fitting (4a-1-02-08-06-s) into the “FUEL IN” port of the AirDog®II. 4-2. Install the 3/8” male J2004 quick connect x 1/8” NPTF (06J2044) into the tank port of the AirDog®II. DO NOT OVER TIGHTEN.
AirDog®II Ford PowerStroke 2011 6.7L AirDog®II & Mounting Brackets Section 4 Installing the AirDog®II & Mounting Brackets on the Truck’s Frame, cont’d. NOTE: The AirDog®II installs easily and is well protected from road debris when mounted on the inside of the driver’s side frame. However, due to clearance issues some vehicles may need to mount the system on the outside of the frame. Mount the AirDog®II as shown in Figure 10 below. Inside Driver’s Side Frame Rail Figure 9 4-6.
AirDog®II Section 5-A Ford PowerStroke 2011 6.7L Fuel Lines AirDog®II Fuel Line to the Engine! 5A-1. Disconnect the fuel supply line coming from the tank to the inlet of OE filter canister. This canister is located on the driver’s side inside frame rail. The fuel canister will stay in place. Figure 12 DISCONNECT HERE 5A-2 Insert the female quick connect end (see figure 13) of the “Pressure Hose Assembly” into the male quick connect fitting previously installed in the port marked “ENGINE”.
AirDog®II Ford PowerStroke 2011 6.7L Fuel Lines Section 5-B Installing the AirDog®II Air/Vapor Return Line! Filler Tube Fuel Return Fitting Hose Clamp Fuel Tank Figure 21 5B-1. Cut filler tube as illustrated, removing 1½ inches. Loose assemble clamps on each end of filler tube. Figure 22 Figure 23 5B-2. Insert “Return Fuel Filler Tube” assembly in filler tube. INSTALL THE FILLER TUBE WITH ARROWS POINTING TOWARD THE TANK!! SEE FIG 22 Properly tighten clamps. 5B-3.
AirDog®II Ford PowerStroke 2011 6.7L Fuel Lines ® Section 5-C Fuel Suction Line for AirDog II 5C-1. Measure and cut the “Suction Hose Assembly” to the desired length. Insert the push lock swivel fitting to the open end of the hose. Use oil to lubricate the hose ID to easy insertion. Then tightly assemble the push lock fitting to the 90° -8 JIC fitting. Finally tightly assemble the 90° fitting to the male -8 JIC fitting previously installed in the “Fuel In” port. Figure 22 5C-2.
AirDog®II Ford PowerStroke 2011 6.7L Electrical Harness Section 6 The AirDog®II is equipped with a relay controlled wiring harness. The AirDog®II wiring harness! AirDog®II Pump Motor Lead Pressure Sensor/Switch Lead* Indicator Light Lead* Battery Positive Lead Battery Negative Lead Mini Fuse Tap Relay Lead Figure 27 CAUTION: If the OPTIONAL Low Pressure Indicator Light is not used, be sure to insulate the two (2) #10 Indicator Light connectors to prevent accidental contact.
AirDog®II Ford PowerStroke 2011 6.7L Electrical Harness Section 6 Connecting the AirDog®II Relay Control Lead 6-2. Route the AirDog®II 'Relay activation lead', the Red (+) wire with the mini fuse tap attached, to the under hood fuse panel located on the driver side fire wall. Connect the fuse tap to a run/start/key on hot circuit. We used fuse #56. Be sure to reinstall the fuse you remove back into our fuse tap so both fuse tap positions are occupied.
AirDog®II Ford PowerStroke 2008 - 2010 6.4L Initial Startup Procedures Section 7 Initial Start Procedure The AirDog®II is a self priming system, however, to prevent potential damage to the system, it is recommended to fill only the pre-filter 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.
AirDog®II Ford PowerStroke 2008 - 2010 6.4L Fuel Filter & Water Separator Section 8 Filter Service Recommendations Plugging of either the fuel filter or the water separator itself will cause low fuel pressure and low flow to the engine. If a low fuel pressure issue exists, replace the fuel filter. Typical fuel filter life is 15-20k miles depending on fuel quality.
AirDog®II Ford PowerStroke 2008 - 2010 6.4L 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, Remove and clean the gerotor. you will need to re-use it. Be very careful not to damage the gerotor. Step 4 Step 5 Remove the O-rings and clean the inside of the gerotor pocket. Step 6 Replace the center gear.
AirDog®II Ford PowerStroke 2008 - 2009 6.4L Pressure Regulator Section 10 AirDog®II DF-100 & DF-165 with Adjustable Pressure Regulator is Preset at 10 PSI! 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.
Installing a New Filter 1. Clean the area around the filter head and groove or seal area. NOTE: Lubricate the seal with oil. Do not use diesel fuel to lubricate the seal. 2. Install a new fuel filter on the filter head. Turn clock-wise until the filter contacts the seal. Tighten the filter one full turn or follow tightening instructions on filter after contact with the seal has been made.
PUREFLOW AIRDOG LIFETIME LIMITED EXPRESS WARRANTY FOR Covered 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.
SELLER hereby provides the following limited warranty as to description, quality, merchantability, fitness for the PRODUCT’S purpose, productiveness, or any other matter of SELLER’S PRODUCT sold herewith. The SELLER 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.
