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PureFlow AirDog®
Airdog® II DF-100, DF-165, & DF-200
2001-2010 Duramax Diesel
#19
PROTECTED BY
CANADIAN PATENT
US PATENTS
AUSTRALIAN PATENT
2,108,391
5,355,860; 5,746,184; 6,729,310
2005101054
NEW ZEALAND PATENT
532356
Additional Foreign Patents Pending in Europe, South America, Mexico, Japan, and China!
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Summary of Contents for PureFlow AirDog AirDog II DF-100
- Page 1 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel PROTECTED BY CANADIAN PATENT US PATENTS AUSTRALIAN PATENT 2,108,391 5,355,860; 5,746,184; 6,729,310 2005101054 NEW ZEALAND PATENT 532356 Additional Foreign Patents Pending in Europe, South America, Mexico, Japan, and China!
- Page 2 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel SMALL and COMPACT 7” Long X 3.2” Wide X 10” Tall...
- Page 3 The AirDog II DF-200 is recommended for Ultra High Performance Duramax diesel engines. PureFlow AirDog products are manufactured in Shelbyville Indiana by a team of skilled workers with unsurpassed attention to detail and using the most stringent quality assurance. TYPICAL INSTALLATION LAYOUT...
- Page 4 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel 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.
- Page 5 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 1 Table of Contents TABLE OF CONTENTS Section 1……………………………….……..……...………..Table of Contents Section 2……………………………………..Installation & Safety Guidelines Section 3……………………………….………………………….…….Parts List INSTALLATION PROCEDURES Section 4……………………..……….………Fittings, Brackets, and Mounting Fuel Lines Section 5…………………………………………………….Fuel Line Assembly...
- Page 6 3. The installation recommendations contained herein are suggested installation guidelines only. Individual installations may vary. 4. If any installation procedure is uncertain, contact PUREFLOW AIRDOG for technical assistance. When installing the AirDog® fuel lines be sure to keep the ORIGINAL ENGINE RETURN LINE...
- Page 7 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 3 Parts List ® AirDog II Parts List IMAGE DESCRIPTION PART NUMBER DF-100 ® AirDog DF-165 DF-200 ® AirDog II Mounting Bracket 001-3C-0004 Mounting Hardware Kit, 901-61-0102-PM-C 010-3C-0002...
- Page 8 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel ILLUSTRATION OF QUICK CONNECT COMPONENTS...
- Page 9 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 4 Fittings, Brackets, and Mounting Installing the J2044 Quick Connect Fittings into the AirDog®II OR AirDog®II-4G Filter Base 4-1. Dip the threaded end of the 1/2” male J2044 quick connect X 9/16” UNF (08J2044916UNF) fittings into clean motor oil and hand-thread into the “ENGINE”...
- Page 10 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 4 (Continued) Fittings, Brackets, and Mounting 4-3. Assemble the AirDog mounting bracket (001-3C-0004) to the frame bracket (010-3C- 0001) using the spacer (010-3C-0003-A-P) as shown in figure 5 using the four bolts, lock washers, and nuts included in the mounting bracket hardware kit (figure 6).
- Page 11 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 4 (Continued) Fittings, Brackets, and Mounting 4-6. Clamp the frame between the AirDog® bracket assembly and the backing plate (figure 9) using the 3/8” bolts, lock washers, and nuts included in the kit. You will need two 9/16”...
- Page 12 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 5 Fuel Line Assembly Assembling the Fuel Lines This kit includes a length of fuel line and separate fuel line ends to allow for much cleaner looking installations! Assemble the fuel lines as you install them.
- Page 13 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 6A Fuel Lines (Supply Line to Engine) ® Installing the AirDog II Fuel Supply Line to the Engine To install the AirDog® II 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 (Figure 17).
- Page 14 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 6A (Continued) Fuel Lines (Supply Line to Engine) 6A-3. Assemble one end of the hose (Reference section 5) using fuel line end FCQ12S and plug it into the J2044 male connection on the factory fuel line to where the factory suction line was just removed from behind the fuel cooler in the previous step.
- Page 15 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 6B Fuel Lines (Return Line to Tank) ® AirDog II Fuel Return Line Installing the Filler Neck Tee in the Filler Tube 6B-1. Cut filler tube as illustrated in figure 20, removing ½ inch of hose. Loose assemble clamps on each end of filler tube before the filler tube is pushed in.
- Page 16 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 6C Fuel Lines (Suction Line from Tank) ® Fuel Suction Line for AirDog 6C-1. Assemble one end of the hose (Reference section 5) using fuel line end FCQ12S and plug it into the J2044 male connection in the AirDog®...
- Page 17 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 7 Wiring Harness ® AirDog Wiring Harness Install WIRING DIAGRAM MINI-TAP RELAY TRIGGER LEAD INDICATOR LIGHT LEADS AirDog® MOTOR LEAD PRESSURE SWITCH LEAD* FUSE HOLDER RELAY WITH 20A FUSE...
- Page 18 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 7 (Continued) Wiring Harness ® Connecting the AirDog Relay Control 7-2. 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 7-3.
- Page 19 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 7 (Continued) Wiring Harness Connecting the power supply leads Continued 7-3B. Should you choose to connect the power supply leads directly to the battery, connect the Red (+) led to the Positive (+) post of the driver’s side battery. Connect the Black (-) lead to the Negative (-) post of the same battery.
- Page 20 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 8 Initial Startup Procedure INITIAL START PROCEDURE ® 8-1. The AirDog II is a self-priming system, however, to prevent possible damage to the system, it is recommended to fill the water separator with diesel fuel before initial startup.
- Page 21 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 9 Fuel Filter and Water Separator 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. Typical fuel filter life is 15-20k miles depending on fuel quality.
- Page 22 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 10 Cleaning the Gerotor Assembly CLEANING DEBRIS/CHECKING FOR DAMAGE IN/TO THE GEROTOR ASSEMBLY STEP 3: Remove and clean STEP 1: Remove the four (4) STEP 2: Carefully remove the Gerotor.
- Page 23 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 11 Pressure Regulator Adjustment AirDog®II AND AirDog®II-4G ADJUSTABLE FUEL PRESSURE REGULATOR The AirDog®II-4G rises to a new level of performance with an adjustable fuel pressure regulator machined from stainless steel with a double O-ring seal system and a soft seat piston.
- Page 24 PureFlow AirDog® AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel Section 12 Filter Maintenance 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.
- Page 25 SEPARATORS. Any PRODUCT that is in question of Warranty must be returned, shipped prepaid, to PureFlow AirDog. All Warranty claims are subject to the approval of PureFlow AirDog. If it is determined that a Warranty claim exists, PureFlow AirDog will, at its sole discretion, replace the defective PRODUCT with a comparable PRODUCT, repair the defective PRODUCT, or refund the BUYER”S purchase price in exchange for the PRODUCT.
- Page 26 Serial Number and Model Number available for the Technician when the call is made. This will expedite all steps of the process. The customer performs any and all tests requested by the PureFlow AirDog Technician. This is done to isolate the potential problem while eliminating potential installation or maintenance related issues,...
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