#18 DF-100 & DF-165 INSTALLATION MANUAL PLEASE READ THE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION CHEVY DIESEL TRUCKS 1992 thru 2000 High Performance Fuel System With New Quick Connect Components! 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 DEMAND FLOW SERIES FLOWS ONLY THE AMOUNT OF FUEL THE ENGINE DEMANDS SMALL and COMPACT 7” Long X 3.
OVERVIEW Welcome to PureFlow AirDog Fuel Air Separation, Filtration and Delivery System for the Diesel Engine! The AirDog®II Fuel Air Separation system is a Premium replacement lift pump and filtration system for the Chevy 6.5 Litre diesel engine. A complete installation kit is included. The AirDog®II delivers clean fuel to the engine free of virtually all air/vapor and at a positive flow. Thus, allowing the engine “test cell” performance and efficiency, while in “real world” use.
QUICK CONNECT COMPONENT OVERVIEW Provided in this is an OE style quick connection system. This system works to allow for 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.
AirDogII® 1992-2000 Chevy 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® & Mounting Brackets FUEL LINES Section 5 A……………………………………………...….AirDog® To Engine Section 5 B……………………......….….……Fuel Tank Supply to AirDog® Section 5 C……………………..………………..….
AirDogII® 1992-2000 Chevy Diesel Installation & Safety Guidelines Section 2 AirDog® MODEL DF-100 & DF-165 The installation of your AirDog® 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 1992-2000 Chevy Diesel Parts List Section 3 AirDog® Parts List 1 Installation Manual 1 AirDog® 1 AirDog® Mounting Bracket 201-1-0201 FP-100 Or FP-150 001-3C-0004 Mounting Bracket Hardware Kit (Included In) 901-61-0102-PM-C 1 010-3C-0002PC 010-3C-0001PC 010-3C-0003-A-P 1 Frame Bracket 1 Spacer 1 Wiring Harness 1 Return Fuel Filler Tube (with 2 Clamps) 1 1 Bundle of Plastic Ties Suction Hose Assembly 5H-2-1-06/12 WAP110-8-5 1 Return Hose Assembly WAP112-8-8 1 Pressure H
ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
AirDogII® 1992-2000 Chevy Diesel AirDog II & Mounting Brackets ® Section 4 Installing the AirDog® II & Mounting Brackets on the Truck’s Frame! Figure 2 4-1. Figure 3 Assemble the AirDog II mounting bracket to the frame bracket. Figure 4 4-2. Figure 5 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. Out to ENGINE 4-3.
AirDogII® 1992-2000 Chevy 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 8 4-5. Figure 9 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. Figure 10 4-6.
AirDogII® 1992-2000 Chevy Diesel Fuel Lines Section 5 Installing the AirDog® Fuel Supply Line to the Engine 5A-1. Remove the factory electric fuel Pump mounted on the driver’s side frame rail. Figure 11 NOTE: Assemble the compression fitting to the -8 JIC flare fitting. 5A-2. Cut the steel fuel line that goes to the engine and install a 3/8” compression fitting with a 3/8” NPT female x -8 JIC on the end of that line.
AirDogII® 1992-2000 Chevy Diesel Fuel Lines Section 5A Installing the AirDog® Fuel Supply Line to the Engine, cont’d 5A-5. Install a straight -8 swivel x 1/2" Push Lock fitting on the cut end of the fuel line. Lubricate the barb end of the Push Lock fitting with oil. Push the fuel line completely onto the barb end of the fitting. Figure 15 Figure 16 5A-6. Connect the swivel fitting to the compression fitting previously installed in step 5A-2.
AirDogII® 1992-2000 Chevy Diesel Fuel Lines Section 5B Installing the Fuel Supply Line from the fuel tank to the AirDog® 5B-1. Cut the steel fuel line that goes to the engine and install a 3/8” compression fitting with a 3/8” NPT female x -8 JIC on the end of that line. Figure 18 5B-2. Insert the female quick connect end (see figure 19) of the “Suction Hose Assembly” to the male fitting installed in the “Fuel In” port during step 4-3 of this manual.
AirDogII® 1992-2000 Chevy Diesel Fuel Lines Section 5-C Fuel Return Line from the AirDog® to the Tank Installing the fuel 'Return to Tank' assembly in Filler Tube Filler Tube Fuel Return Fitting Hose Clamp Fuel Tank Figure 23 5C-1. Cut filler tube as illustrated, removing ½ inch. Loose assemble clamps on each end of filler tube. Figure 24 Figure 25 5C-2. Insert “Return Fuel Filler Tube” assembly in filler tube.
AirDogII® 1992-2000 Chevy Diesel Electrical Harness Section 6 The AirDog® is equipped with a relay controlled wiring harness. WIRING DIAGRAM (In Red) Figure 41 The AirDog® wiring harness! AirDog® Pump Motor Lead Pressure Sensor/Switch Lead Indicator Light Lead Battery Positive Lead Battery Negative Lead Mini Fuse Tap Relay Lead Figure 42 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.
AirDogII® 1992-2000 Chevy Diesel Electrical Harness Section 6 Connecting the AirDog® Relay Control 6-2. Remove the plastic housing covering 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/run position. Connect the Red Relay Trigger wire with the mini fuse tap to that terminal.
AirDogII® 1992-2000 Chevy 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 49 6-5. Route the wiring harness to the AirDog® and connect the 2 pin Deutsch connector to the corresponding connector on the AirDog®.
AirDogII® 1992-2000 Chevy Diesel Initial Startup Procedures Section 7 INITIAL START PROCEDURE The AirDog® is a self priming system, however, to prevent possible damage to the system, it is recommended to fill 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.
AirDogII® 1992-2000 Chevy Diesel Section 8 Service Recommendations 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. AirDog® 2 Micron Fuel Filter AirDog® WATER SEPARATOR Drain Valve The Water Separator Replace the water separator every other time you change the Fuel Filter or if it becomes damaged or plugged.
AirDogII® 1992-2000 Chevy Diesel AirDog® Fuel Pump Section 9 Cleaning Foreign Debris from the Gerotor Assembly Step 1 Remove the four (4) socket head cap crews that secure the gerotor cap. Step 4 Clean the inside of the gerotor pocket. Step 2 Step 3 Carefully remove the O’ring, Remove and clean the gerotor. you will need to re-use it. Be very careful not to damage the gerotor. Step 5 Replace the O’ring and center gear. Step 6 Align the teeth and install the outer gear.
PureFlow AirDog AirDogII ® 1992-2000 Chevy Diesel Pressure Regulator Section 10 AirDog II DF-100 & 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.
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.
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.
