#7 INSTALLATION MANUAL MODEL FP-100 & FP-150 With New Quick Connect Components! 1999 - 2003 FORD POWERSTROKE 7.3L 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 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 1999 – 2003 7.3L 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 High Pressure Pump Section 5 B……………………...……….……..….……Fuel Return to Tank Section 5 C……………………..……………….….
AirDog® FP-100 & FP-150 Ford PowerStroke 1999 – 2003 7.3L 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.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.
ILLUSTRATION OF QUICK CONNECT COMPONENTS DRAWING NOT TO SCALE 8
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L AirDog® & Mounting Brackets AirDog FP-100 & FP-150 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.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L AirDog® & Mounting Brackets AirDog FP-100 & FP-150 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 for you. Mount the AirDog® so the “FUEL IN” port is directed toward the rear of the vehicle. Figure 11 Figure 12 4-3.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L Fuel Lines AirDog FP-100 & FP-150 Section 5-A Fuel Supply Line from the AirDog® to the High Pressure Pump Remove the original factory fuel supply line at the electric OE lift pump, located on the driver’s side inside frame rail by squeezing the tabs on the end of the connector together. Push the quick connect fitting toward the OE lift pump while firmly depressing the tabs. With the tabs depressed, pull the fitting assembly from the inlet tube.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L Fuel Lines AirDog FP-100 & FP-150 Section 5-A 5A-4 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 5A-4.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L Fuel Lines AirDog FP-100 & FP-150 Section 5-B Fuel Return Line from the AirDog® to the Tank Cont’d 5B-2. Insert “Return Fuel Filler Tube” assembly in filler tube. INSTALL THE FILLER TUBE WITH ARROWS POINTING TOWARD THE TANK!! SEE FIG 22 Properly tighten clamps. 5B-3. Insert the SAE J2044 female quick connect end( see Figure 23) of the “Return Hose Assembly” into the pre-installed male fitting in the port marked “Tank”.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L Fuel Lines AirDog FP-100 & FP-150 Section 5-C Fuel Suction Line for AirDog® FP-100, cont’d! Figure 27 Figure 26 Figure 25 Suction Line Return Line In More Detail To release the quick-connect fitting from the fuel tank suction tube, push the fitting toward the suction tube. With the plastic tabs firmly depressed, pull the fitting assembly from the suction tube. Hold the Quick Connect Fitting square to the suction tube.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L Fuel Lines AirDog FP-100 & FP-150 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 ® Ford PowerStroke 1999 – 2003 7.3L High Flow Suction Tube AirDog FP-100 & FP-150 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 ® Ford PowerStroke 1999 – 2003 7.3L High Flow Suction Tube AirDog FP-100 & FP-150 Section 5-E 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 40. Figure 40 5D-6. Lubricate the bulkhead fitting with motor oil. Pressing firmly, insert the suction tube assembly into the grommet.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L High Flow Suction Tube AirDog FP-100 & FP-150 Section 5-E 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.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L Electrical Harness AirDog FP-100 & FP-150 Section 6 The AirDog® is equipped with a relay controlled wiring harness.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L Electrical Harness AirDog FP-100 & FP-150 Section 6 Connecting the AirDog® Relay Control Lead 6-2. Route the AirDog® 'Relay activation lead', to the fuse panel on the dash to the left of the steering column. Insert the mini fuse tap into a spare fuse holder on the panel that is “hot” when the starter key is turned to the on position. Figure 47 Figure 48 ® 6-3.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L Initial Startup Procedures AirDog FP-100 & FP-150 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.
PureFlow AirDog ® Ford PowerStroke 1999 – 2003 7.3L Fuel Filter & Water Separator AirDog FP-100 & FP-150 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 ® Ford PowerStroke 1999 – 2003 7.3L AirDog® Fuel Pump AirDog FP-100 & FP-150 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 gearotor. you will need to re-use it. Be very careful not to damage the gerotor. Step 5 Replace the O’ring and center 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.
