#6 FP-100 & FP-150 INSTALLATION MANUAL DURAMAX DIESEL POWERED Chevy & GMC TRUCKS 2001 thru 2010 High Performance Fuel System 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 System for the Diesel Engine! The AirDog® Fuel Air Separation System is a Premium Lift Pump and Filtration System with Fuel Air Separation for the DuraMax 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 2001-2010 DuraMax Diesel 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax 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 Return to Tank Section 5 C……………………..…………..
PureFlow AirDog ® AirDog FP-100 & FP-150 Section 2 2001-2010 DuraMax Diesel 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel Parts List Section 3 AirDog® Parts List 1 Installation Manual 1 AirDog® 1 AirDog® Mounting Bracket 201-1-0202 FP-100 Or FP-150 001-3C-0004 Mounting Hardware Kit, 1 901-61-0102-PM-C 010-3C-0002PC 010-3C-0001PC 5E-2-010 1 Frame Bracket 1 Wiring Harness 1 Bundle of Plastic Ties 1 Return Fuel Filler Tube (with 2 Clamps) 1 High Flow Suction Tube (For FP-150’s Only) 1 Grommet (For FP-150’s Only) 1 Spacer 1 Suction Hose A
ILLUSTRATION OF QUICK CONNECT COMPONENTS 8
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel AirDog® & Mounting Brackets Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame! Figure 2 4-1. Assemble the AirDog® mounting bracket to the frame bracket. Figure 4 4-2. Figure 3 Figure 5 Figure 6 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel AirDog® & Mounting Brackets Section 4 Installing the AirDog® & Mounting Brackets on the Truck’s Frame, cont’d! NOTE: The AirDog® can be mounted on the inside or the outside of the frame. Some bed and cab configurations may only allow system to mount on the outside of the frame. Driver’s Side Frame Rail. Figure 9 4-5.
PureFlow AirDog AirDog ® 2001-2010 DuraMax Diesel Fuel Lines Section 5A Installing the AirDog Fuel Supply Line to the Engine To install the AirDog fuel supply line to the engine you must first remove the (flexible) factory fuel line connecting the fuel tank to the frame mounted steel fuel line. It will be the larger of the two lines that are on the frame. NOTE: The fuel tank connections are located behind the tank shield.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel Fuel Lines Section 5A 5A-3. Attach, by pushing, the female 1/2” SAE J2044 quick connect end (Figure 16) of the “Pressure Hose Assembly” onto the factory male quick connect that was disconnected in step 5A-2 (Figure 15). You will hear a “click” when properly connected and the final install will look like image 14. Figure 16 5A-4.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel Fuel Lines Section 5B AirDog® Fuel Return Line! Installing the fuel 'Return to Tank' assembly in Filler Tube Filler Tube Fuel Return Fitting Hose Clamp Fuel Tank Figure 19 5B-1. Cut filler tube as illustrated, removing ½ inches. Loose assemble clamps on each end of filler tube. Figure 20 Figure 21 5B-2. Insert “Return Fuel Filler Tube” assembly in filler tube.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel Fuel Lines Section 5-C Fuel Suction Line for AirDog® FP-100 Only! NOTE: The AirDog® FP-150 requires a High Flow Suction Tube. If you are installing an AirDog® FP-150 skip Section 5C and go to Section 5D for the High Flow suction tube installation instructions! 5C-1. Insert the female quick connect end (see figure 22) of the “Suction Hose Assembly” to the male fitting installed in the “Fuel In” port during step 4-3 of this manual.
AirDog® FP-100 & FP-150 2001-2010 DuraMax Diesel High Flow Suction Tube Section 5-D INSTALLING THE AIRDOG® FP-150 HIGH FLOW SUCTION TUBE NOTE: THE FUEL TANK USED FOR THE FOLLOWING PICTURES IS AN EXAMPLE ONLY AND MAY NOT BE EXACTLY THE SAME AS YOUR TANK. 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel High Flow Suction Tube Section 5-D INSTALLING THE HIGH FLOW SUCTION TUBE, cont’d CAUTION: 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. Be sure the sending unit goes in the same way it was removed. 5D-1. Remove the sending unit from the fuel tank. Figure 30 Figure 31 5D-2.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel 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 ¼” 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 2001-2010 DuraMax Diesel 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 house 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 2001-2010 DuraMax Diesel Electrical Harness Section 6 The AirDog® is equipped with a relay controlled wiring harness.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel Electrical Harness Section 6 Connecting the AirDog® Relay Control 6-2. Remove the plastic housing (skirt) around 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 position.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel Initial Startup Procedures Section 7 INITIAL START PROCEDURE The AirDog® is a self priming system, however, to prevent potential 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax Diesel 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.
PureFlow AirDog ® AirDog FP-100 & FP-150 2001-2010 DuraMax 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.
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.
