#4 FP-100 & FP-150 INSTALLATION MANUAL CUMMINS POWERED DODGE TRUCKS Model Year 2005 TO PRESENT High Performance Fuel System For the 5.9L & 6.7L Engines 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! 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 lift pump and filtration system for the Dodge Cummins 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 2005-Present 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 2005 - Present 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 5.9 CP-3 Section 5 B………………………....………..............AirDog® To 6.7L CP-3 Section 5 C…………………...………….
PureFlow AirDog ® AirDog FP-100 & FP-150 Section 2 Dodge 2005 - Present Installation & Safety Guidelines 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 2005 - Present Parts List Section 3 AirDog® Parts List QTY 1 DESCRIPTION Part Number Installation Manual 201-1-0105 FP-100 Or FP-150 ® 1 AirDog 1 AirDog® Mounting Bracket 001-3C-0004 Mounting Hardware Kit, 1 901-61-0102-PM 1 Frame Bracket 010-3C-0002PC 010-3C-0001PC 1 Wiring Harness 5E-2-014 1 Return Fuel Filler Tube (with 2 Clamps) 001-4A-0150 1 Bundle of Plastic Ties 5H-2-1-06/12 1 High Flow Suction Tube 1 Grommet 1 Spacer 1
3 Push Lock Hose Splice 001-4A-1-0026 2 1/2” Male SAE J2004 Quick Connect x 3/8” NPTF 08J2044-3/8 NPTF ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005- Present 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. Figure 5 Use the spacer block as necessary to clear lines and wiring harnesses on the frame. Adjust the assembly up or down on the frame bracket as necessary for clearance. FUEL IN 4-3.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005 - Present 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 2005 - 2009 Fuel Lines Section 5-A Fuel Supply Line from the AirDog® to the CP-3 For the 5.9L Cummins Engine 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 CP-3 injector pump (Ref. Figure 14). . Figure 14 Figure 15 5A-2.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005 - Present 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 Section 5-B Dodge 2005 - Present cont’d 5B-3. Insert the female quick connect end (see figure 20) of the “pressure hose assembly” into the male quick connect fitting previously installed in the port marked “ENGINE”. You will hear a “click” when it connects. Figure 20 5B-4. Connect the other end of the “pressure hose assembly” to the inlet fitting installed in step 5B-2.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005- Present 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 22 5C-1. Cut filler tube as illustrated, removing ½ inches. Loose assemble clamps on each end of filler tube. Figure 23 Figure 24 5C-2. Insert “Return Fuel Filler Tube” assembly in filler tube.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005- Present Fuel Lines Section 5-D INSTALLING THE IN-TANK FUEL PUMP BYPASS SUCTION TUBE! NOTE: The AirDog® installation kit includes a Suction Tube to by pass the “in-tank fuel pump on the 2005 - Present Dodge. To install the 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 2005- Present High Flow Suction Tube Section 5-D 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. 5D-1. Remove the collection basket. Figure 30 Figure 31 5D-2.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005-Present High Flow Suction Tube Section 5-D INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d 5D-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 36. Figure 36 5D-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 2005-Present High Flow Suction Tube Section 5-D INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d Figure 40 5D-11 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. Push lock splices have been included if you choose to remove the excess hose 5D-12 If the fuel tank was dropped to install the suction tube, re-install the fuel tank.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005 - Present Electrical Harness Section 6 The AirDog® wiring harness features water proof Deutsch connectors, relay, and fuse holder. When properly installed, the AirDog® is controlled by the engine’s ECM. WIRING DIAGRAM (In Red) Figure 41 ® The AirDog is activated by the ECM through a relay controlled wiring harness connecting directly to the original ECM Deutsch pump connector.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005 - Present Electrical Harness Section 6 Securing the Relay and Fuse Holder to the Vehicle 6-1. Secure the relay and fuse holder to the vehicle. Figure 43 Figure 44 Connecting the AirDog® Power Lead Jumpers 6-2. Remove the factory wire harness connection from the top of the fuel module as seen in (Figure 45) Figure 45 6-3. Plug the AirDog female power lead jumper into the top of the fuel module.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005 - Present Electrical Harness, cont’d Section 6 OR 6-7. 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 Section 7 Dodge 2005 - Present Initial Startup Procedures cont’d INITIAL START PROCEDURE The AirDog® 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 pre-filter with diesel fuel. 7-2. Turn the starter key to the on/run position. NOTE: It may be necessary to momentarily engage the starter in order for the ECM to energize the AirDog®.
PureFlow AirDog ® AirDog FP-100 & FP-150 Dodge 2005 - Present Fuel Filter & Water Separator Cont’d Fuel Filter & Pre-Filter 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.
PureFlow AirDog AirDog FP-100 & FP-150 Dodge 2005 - Present Pressure Regulator Upgrade Section 9 Changing the Regulator Spring The AirDog® is shipped from the factory with the fuel pressure preset. For the 2005-2009 Dodge Cummins the AirDog® fuel outlet pressure is preset at 15 PSI (±2). However, for some applications, you may desire to increase the pressure output from your AirDog®. To do this, you will need to purchase and install a higher tension spring.
Section 10 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 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.
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 Cover 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.
