INSTALLATION MANUAL #33 6.4L Ford PowerStroke 2008-2010 MODEL RP-100 & RP-150 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.
Wire Screen Insert In Fuel Inlet To Protect the Gerotor Fuel Inlet NOW On Left Side Adjustable Regulator 2
OVERVIEW Welcome to the Raptor™ Fuel Pump The Raptor™ Fuel Pump is a Premium replacement lift pump for the Ford PowerStroke 6.4L diesel engine. A complete installation kit is included. The 6.4L PowerStroke Diesel Engine is a Common Rail engine and requires ONLY 8-10 PSI fuel pressure. The Raptor™ output pressure for the PowerStroke 6.4L diesel engine is factory set at 10 PSI. You may wish to re-adjust the pressure at the time of installation.
QUICK CONNECT COMPONENT OVERVIEW Provided in this kit is an OE style quick connection system. This system allows 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.
Raptor™ 100 & 150 2008 - 2009 Ford PowerStroke Table of Contents Section 1 TABLE OF CONTENTS Section 1…………………………………….……….….…..Table of Contents Section 2……………………………….……………….…...Safety Guidelines Section 3……………………………….…………………….….…….Parts List INSTALLATION PROCEDURES Section 4…………………….……….…………Raptor™ & Mounting Brackets FUEL LINES Section 5 A………………………………..….……….….....Raptor™ to Engine Section 5 B.……………………...………..……….….…Fuel Tank to Raptor™ ELECTRICAL HARNESS Section 6…..…………………………………..…….……….
Raptor™ 100 & 150 2008 - 2010 Ford PowerStroke Installation & Safety Guidelines Section 2 Raptor™ MODEL RP-100 & RP-150 The installation of the Raptor™ Fuel Pump can be made relatively easy by following the steps outlined in this manual. 1. Inventory the package components completely. Notify PUREFLOW AIRDOG. immediately of any parts missing or damaged. 2. Read the installation manual and understand how the system operates before beginning installation. 3.
Raptor™ 100 & 150 2008 - 2010 Ford PowerStroke Parts List Section 3 Parts List QTY DESCRIPTION Part Number 1 Installation Manual 1 Raptor™ 201-1-0306 RP-100 1 Frame Bracket 1 Wiring Harness 1 Mounting Hardware Kit Or RP-150 010-3C-0002PC 010-3C-0001PC 5E-2-012 901-61-0102-PM-RP-F 1 1 Bundle of Plastic Ties Spacer 5H-2-1-06/12 010-3C-0003-A-P 1 Suction Hose Assembly WAP110-8-8-90 1 Pressure Hose Assembly WAP121-8-8 1 2 Customer Service Oring Replacement Kit Push Lock Hose Splice
ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
Raptor™ 100 & 150 Section 4 2008 - 2010 Ford PowerStroke Raptor™ Fuel Pump & Mounting Brackets Mounting the Raptor™ to the Truck’s Frame. The Raptor™ Fuel Pump is best mounted with the electric motor up, as shown. 4-1. Install 1/2” O-ring Boss X 3/4” male fitting (08J2044-3/4UNF) into the Raptor™ port marked “IN”. FUEL “IN” PORT FUEL “OUT” PORT Figure 2 4-2. Install 1/2” O-ring Boss X 3/4” male fitting (08J2044-3/4UNF) into the port marked “OUT”. Properly torque the fitting.
Raptor™ 100 & 150 Section 5-A 2008 - 2010 Ford PowerStroke Fuel Lines Raptor Fuel Line to the Engine. 5A-1. Disconnect the fuel supply line to the engine from the OE fuel pump. This pump is located on the driver’s side inside frame rail. Fuel Pump with 1/2” Quick Connect Fitting To Engine Figure 5 DISCONNECT HERE View from Front Figure 6 View From Below 5A-2.
Raptor™ 100 & 150 2008 - 2010 Ford PowerStroke Fuel Lines Section 5B Fuel Suction Line for the Raptor. 5B-1. Insert the quick connect end (see figure 8) of the “Suction Hose Assembly” to the male fitting install in the fuel “IN” port during step 4-1 of this manual. A “click” will be heard when the fitting is properly connected. Figure 8 5B-2. Remove the original fuel suction line Quick Connect fitting from fuel tank by squeezing the tabs on the end of the connector together.
Raptor™ 100 & 150 2008 - 2010 Ford PowerStroke Electrical Harness Section 6 Figure 12 Installing the Raptor™ Fuel Pump wiring harness. Ground Wire Hot Lead The Raptor™ wiring harness. Water Proof Fuse Raptor Pump Lead Figure 13 6-1. To connect the Power Supply Lead to the Raptor™. Insert the 2 pin Deutsch connector on the end of the wiring harness into the corresponding connector on the Raptor™. Figure 14 6-2.
Raptor™ 100 & 150 2008 - 2010 Ford PowerStroke Final Check List Section 7 INITIAL START PROCEDURE 7-1. Turn the starter key to the on/run position. 7-2. While the Raptor™ Fuel Pump is on, bleed the fuel line to the filter canister by loosening the fuel line connection at the canister. As soon as the line is purged of air and fuel is observed, properly tighten the fuel fitting. NOTE: put a rag or shop towel over and around the fitting to prevent splatter.
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.
