#9 INSTALLATION MANUAL MODEL FP-100 & FP-150 With New Quick Connect Components! FORD POWERSTROKE 6.4L DIESEL ENGINE 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 lift pump and filtration system for the Ford PowerStroke 6.4L 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 QUICK CONNECT COMPONENT OVERVIEW Provided in this kit 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.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L 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……………………………………………..……….Fuel To Engine Section 5 B……………………...……….……..….………Fuel Return to Tank Section 5 C……………………..……………….…….
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L 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. 3.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.
ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L AirDog® & Mounting Brackets Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame. Figure 2 4-1 Figure 3 Figure 4 Assemble the AirDog® mounting bracket to the frame bracket. Use the spacer block to adjust the AirDog® to clear lines and wiring harnesses on the frame. Also adjust the assembly up or down on the frame bracket as needed for clearance.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L AirDog® & Mounting Brackets Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame, cont’d. NOTE: You may attach the AirDog® to the bracket either before or after attaching the assembly to the frame, whichever is easier. Mount the AirDog® so the “FUEL IN” port is directed toward the rear of the vehicle.
AirDog® FP-100 & FP-150 Section 5-A Ford PowerStroke 2008 6.4L Fuel Lines AirDog®II 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.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L Fuel Lines Section 5-B 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 18 5B-1. Cut filler tube as illustrated, removing ½ inch. Loose assemble clamps on each end of filler tube. Figure 19 Figure 20 5B-2. Insert “Return Fuel Filler Tube” assembly in filler tube.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L Fuel Lines Section 5-C Section 5-C: 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 5-C and go to section 5D. 5C-1. Insert the female quick connect end (see figure 21) of the “Suction Hose Assembly” to the male fitting installed in the “Fuel In” port during step 4-3 of this manual. A “click” will be heard when the fitting is properly connected.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L Fuel Lines Section 5-D 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 Ford PowerStroke 2008 6.4L 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 Ford PowerStroke 2008 6.4L 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 38. Figure 35 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 Ford PowerStroke 2008 6.4L High Flow Suction Tube Section 5-D INSTALLING THE HIGH FLOW SUCTION TUBE, Cont’d. 5D-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.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L Electrical Harness Section 6 The AirDog® is equipped with a relay controlled wiring harness. WIRING DIAGRAM (In Red) High Pressure Fuel Pump Figure 39 The AirDog® wiring harness.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L Electrical Harness Section 6 Connecting the AirDog® Relay Control Lead Figure 42 6-3. Route the AirDog® 'Relay activation lead', the Red (+) wire with the mini fuse tap attached, to the OE fuel pump. Remove the mini fuse tap and splice the relay lead to the OE fuel pump lead. NOTE: The power supply leads can be connected to the battery or the alternator.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L Initial Startup Procedures Section 7 INITIAL START PROCEDURE The AirDog® is a self priming system, however, to prevent potential damage and reduce the life expectancy of the system, it is recommended to pre-fill only the water separator with diesel fuel before initial startup. 7-1. Pre-fill the water separator with diesel fuel. 7-2. Turn the starter key to the on/run position. 7-3.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 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. 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.
AirDog® FP-100 & FP-150 Ford PowerStroke 2008 6.4L AirDog® Fuel Pump Section 9 Cleaning Foreign Debris from the Gearotor Assembly Step 1 Remove the four (4) button head cap crews that secure the gearotor cap. Step 2 Step 3 Carefully remove the O’ring, Remove and clean the gearotor. you will need to re-use it. Be very careful not to damage the gearotor. Step 4 Clean the inside of the gearotor pocket. Step 5 Replace the O’ring and center gear. Step 6 Align the teeth and install the outer gear.
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.
