#3 FP-100 & FP-150 INSTALLATION MANUAL CUMMINS POWERED DODGE TRUCKS Model Year 1998 ½ THROUGH 2004 High Performance Fuel System With New Quick Connect Components! 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! 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® Fuel Air Separation system is a Premium replacement lift pump and filtration system for the Dodge Cummins 24 Valve diesel engine. A complete installation kit is included. The AirDog® 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 QUICK CONNECT COMPONENT OVERVIEW Provided in this kit is an OE style Quick Connect 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 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® & Mounting Brackets FUEL LINES Section 5 A……………………………......…1998.5-’02 AirDog® To VP-44 Section 5 B……………………………….…...…..2003-’04 AirDog® to CP3 Section 5 C……………………...……….
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 Installation & Safety Guidelines Section 2 AirDog® MODEL FP-100 & FP-150 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.
2 1/2” Male SAE J2004 Quick Connect x 3/8” NPTF 1 17 PSI Spring 08J2044-3/8 NPTF 1V-1-00003 ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 AirDog & Mounting Brackets ® Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame! Figure 2 4-1. Figure 3 Assemble the AirDog® mounting bracket to the frame bracket. Figure 4 4-2. 4-3. 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 AirDog & Mounting Brackets ® Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame, cont’d! NOTE: The AirDog® can be mounted on either the inside or the outside of the frame, as space or personal choice dictates. Mount The AirDog® Outside The Frame OR Figure 8 Figure 9 Inside The Frame Figure 10 Figure 11 For this installation, the AirDog® is mounted inside the frame! 4-5.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 Fuel Lines Section 5-A This section is for the 1998.5 – 2002 Dodge Fuel Supply Line from the AirDog® to the VP-44 The AirDog® fuel filter has a 2 micron media. When installing the AirDog® fuel system it is recommended to bypass the factory filter canister. 5A-1. Remove the “banjo bolt” and the original factory fuel supply line at the fuel inlet port of the VP44 injector pump (Ref. Figure 14). CAUTION: Do not over torque the 12mm fitting.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 Fuel Lines Section 5-A 5A-6. It is advised to remove the factory supply lines between the tank and the filter canister. Also remove the factory supply line between the filter canister and the injection pump. Then plug the ports on the filter canister. This will prevent fuel spillage.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 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 19 5C-1. Cut filler tube as illustrated, removing ½ inches. Loose assemble clamps on each end of filler tube. Figure 20 Figure 21 5C-2. Insert “Return Fuel Filler Tube” assembly in filler tube.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 Fuel Lines Section 5-D Fuel Suction Line for AirDog® FP-100! NOTE: The AirDog® FP-150 requires a High Flow Suction Tube. If you are installing an AirDog® FP-150 skip Section 5D and go to section 5E for these installation instructions! Connecting the Fuel Supply Line from the Tank to AirDog® FP-100 Figure 22 5D-1.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 Fuel Lines Section 5-D Fuel Suction Line for AirDog® FP-100, cont’d 5D-2 Very Important: After removing the factory line check to make sure that the blue plastic retainer was removed with the line. If the blue retainer remained attached to the tank tube, it MUST be removed before the new fuel line Quick Connect will connect and seat to the tank suction tube. 5D-3.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 High Flow Suction Tube Section 5-E INSTALLING THE AIRDOG® FP-150 HIGH FLOW SUCTION TUBE The AirDog® 150 includes a ½” High Flow suction tube to accommodate the high flows of this system. To install the ½ suction tube it is necessary to either drop the fuel tank or to lift the truck bed. NOTE: Should you choose to drop the fuel tank, support the tank as it is when it is installed on the truck.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 High Flow Suction Tube Section 5-E INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d NOTE: The fuel tank used for the pictures is an example only and may not be exactly the same as your tank. IMPORTANT: Select a location for the suction tube that has adequate clearance below the bed. Also consider that under hard acceleration, fuel will migrate toward the back of the fuel tank. 5E-1. Remove the collection basket. Figure 34 Figure 35 5E-2.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 High Flow Suction Tube Section 5-E INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d 5E-5. Measure and cut the suction tube to a length that will allow approximately 1/8” clearance off the bottom of the tank. It is suggested to form the end of the tube similar to Figure 40. Figure 40 5E-6. Lubricate the bulkhead fitting with motor oil. Pressing firmly, insert the suction tube assembly into the grommet.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 High Flow Suction Tube Section 5-E INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d 5E-10. If the fuel tank was dropped to install the suction tube, re-install the fuel tank. If the truck bed was removed, reinstall the bed. Section 6 Electrical Harness The AirDog® is equipped with a relay controlled wiring harness. When properly installed, the AirDog® is controlled by the ECM.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 Electrical Harness Section 6 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. Securing the Relay and Fuse Holder to the Vehicle 6-1. Secure the relay and fuse holder to the vehicle. Figure 46 Figure 47 Connecting the AirDog® Relay Control to the ECM 6-2. Disconnect the OE fuel pump lead from the ECM pump lead.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 Electrical Harness, cont’d Section 6 OR 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. Figure 51 6-5. Route the wiring harness to the AirDog® and connect the 2 pin Deutsch connector to the corresponding connector on the AirDog®.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 1998.5 - 2004 Initial Startup Procedures Con’t Section 7 EXCESSIVE HEAT AND SECURED TO PROTECT FROM CHAFFING AND ABRASION. RECHECK ALL ELECTRICAL LINES, SECURE AS NECESSARY. Checking Pump Noise! NOTE: Each AirDog® has been manufactured in a Quality Controlled process and wet tested for operation and performance before shipment. This is a very quiet and smooth running system.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1998.5 - 2004 Fuel Filter & Pre-filter Cont’d Section 8 The Water Separator Replace the water separator every other time you change the Fuel Filter or if it becomes damaged or plugged. It is suggested to check/drain the water separator every three months or as needed should you experience excessive ‘water in fuel’ conditions. When installing the water separator, be sure to clean the underside of the AirDog® base.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1998.5 - 2004 Pressure Regulator Upgrade Section 9 Step-2. Remove the ‘Return to Tank’ fuel line fitting exposing the regulator spring. Step-3. Remove the ball and spring. Figure 56 Figure 57 Figure 58 Step-4. Install the new regulator spring by reversing the steps 1 thru 4. Be sure to place the regulator ball in the regulator seat before inserting the spring. Properly torque the return line fitting and swivel connection when finishing.
PureFlow AirDog AirDog® 100 & 150 Dodge Cummins 1998.5 - 2004 AirDog® Fuel Pump Section 10 Step 7 Install the Gerotor cap. Be very careful to index the cap to position the wide space between the half moon cuts to the bottom. Step 8 Replace the cap into position. Be very careful, do not pinch the O-ring. Torque the cap screws. in an opposing pattern. 25 1. 4. 3. 2.
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.
