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Summary of Contents for PureFlow AirDog AirDog II-5G
- Page 1 PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke 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-5G DF-165 2011-2016 6.7L Powerstroke SMALL and COMPACT 7” Long X 3.2” Wide X 10” Tall...
- Page 3 2011-2016 6.7L Powerstroke OVERVIEW Thank you for your purchase and welcome to PureFlow AirDog’s AirDog®II-5G fuel air separation and delivery system for the 2011-2016 6.7L. The AirDog®II-5G is an all in one premium fuel pump and filtration system for the 6.7L.
- Page 4 PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke QUICK CONNECT COMPONENT OVERVIEW Provided in this kit is an OE style quick connection system. This system works to allow 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.
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Page 5: Table Of Contents
PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 1 Table of Contents TABLE OF CONTENTS Section 1…………………………….…….….………....…Table of Contents Section 2…………………………..……...…Installation and Safety Guidelines Section 3………………………….……….….……………………….….….Parts List INSTALLATION PROCEDURES Section 4…………………….…….……..…………………….Fittings and Brackets Section 5………………………………………………………….…..Pump Mounting FUEL LINES Section 6………………………………………….………………Fuel Line Assembly Section 7A…………………………………..……..Supply Line to Engine Crew Cab... -
Page 6: Section 3
II-5G can be relatively easy by following the steps outlined in this manual, and: 1. Inventory the package components completely. Notify PUREFLOW AIRDOG immediately of any missing or damaged parts. (877-421-3187) 2. Read the installation manual completely. Understand how the system operates and take note of installation recommendations before beginning installation. - Page 7 PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 3 Parts List PowerStroke Parts List DESCRIPTION PART NUMBER IMAGE ® AirDog II-5G DF-165 ® AirDog II-5G Mounting Bracket 001-3C-0004 Mounting Hardware Kit, 901-61-0102-PM-F11 010-3C-0002 Frame Bracket 010-3C-0001 Wiring Harness 5E-2-010-HD...
- Page 8 PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke ILLUSTRATION OF COMPONENTS...
- Page 9 2011-2016 Powerstroke Section 4 Fittings, Brackets, and Mounting Installing the Supplied Fittings Into the AirDog II-5G Base 4-1. Dip the threaded end of the 08J2044-3/4UNF fitting into clean motor oil and hand- thread into the “ENGINE” and “INLET” ports of the AirDog®II-5G filter base as illustrated in figures 1, 2, and 3.
- Page 10 PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke 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 4 using the four bolts, lock washers, and nuts included in the mounting bracket hardware kit (figure 5).
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Page 11: Section 4
PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 5 Frame Rail Mounting Frame Rail Mounting 5-1. Start by disconnecting all four of the fuel lines from the factory fuel pump. NOTE: The supply lines are Yellow and the return lines are Blue. -
Page 12: Section 5
PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 5 Frame Rail Mounting 5-3. Next, remove the four nuts on the frame rail that secure the factory fuel pump and remove the factory pump. Figure 10 Figure 11 5-4. While there is clear access to the factory suction line, cut the rubber line off of the hard line. -
Page 13: Section 6
PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 5 Frame Rail Mounting 5-5. Clamp the frame between the AirDog®II bracket assembly and the backing plate using the 3/8” bolts, lock washers, and nuts included in the kit. Tighten using a pair of 9/16”... - Page 14 PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 6 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.
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Page 15: Section 7A
7A-1. The factory supply line (Yellow) that was disconnected from the factory fuel pump can be connected directly to the AirDog II-5G “Engine” port. Be sure the fuel line does not kink. If need be, loosen the sandwich plates to slide the pump and re-tighten. -
Page 16: Section 7B
Section 7B Supply Line Single Cab Supply Line from the AirDog II-5G Outlet to the Factory Engine Supply Line for Single Cab Applications 7B-1. Remove the other end of the factory fuel pump outlet line from the hard steel line that is located above the crossmember. - Page 17 PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 7B (Continued) Supply Line Single Cab 7B-3. Run the fuel line along the frame as mentioned in step 6-3 to the “Engine” port in the AirDog®. Cut the fuel line to length and insert fuel line end FQC12S per step 6-1. Once the fitting is installed, connect it to the male J2044 fitting in the “Engine”...
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Page 18: Section 9
Section 8 Suction Line from Tank Suction Line from the Factory Suction Line to the AirDog II-5G Inlet 8-1. First, lubricate the inside of one end of the HS14 fuel line with clean motor oil and slide it over the suction line to where the factory piece was cut off in step 5-4. Refer to... - Page 19 AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 9 Return Line Retrun Line from the AirDog II-5G to the Factory Engine Return 9-1. Take the 001-4B-1-0067 return “Y,” included in the kit, and plug it into the two blue factory lines. Be sure to lock the connectors and to have the outlet of the “Y” facing toward the AirDog Return port.
- Page 20 PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 10 Wiring Harness ® AirDog Wiring Harness Install WIRING DIAGRAM MINI-TAP RELAY TRIGGER LEAD AirDog® MOTOR LEAD FUSE HOLDER RELAY WITH 20A FUSE BATTERY NEGATIVE LEAD BATTERY POSITIVE LEAD Figure 35 Secure the Relay and Fuse Holder to the Vehicle 10-1.
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Page 21: Section 10
PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 10 (Continued) Wiring Harness ® Connecting the AirDog II Relay Control Lead ® 10-2 Route the AirDog II 'Relay activation lead', the Red (+) wire with the mini fuse tap attached, to the under hood fuse panel located on the driver side fire wall. Connect the fuse tap to a run/start/key on hot circuit. -
Page 22: Section 11
PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 11 Initial Startup Procedure INITIAL START PROCEDURE ® 11-1. 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 23: Section 12
PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 12 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 24: Section 13
PureFlow AirDog® AirDog® II-5G DF-165 2011-2016 6.7L Powerstroke Section 13 Cleaning the Gerotor 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. Be very careful... -
Page 25: Section 14
GAUGE. TOO MUCH OR TOO LITTLE PRESSURE MAY CAUSE DAMAGE TO THE INJECTION SYSTEM! Every AirDog II-5G has a 90-degree brass fitting in the pump to where you can add a fuel pressure gauge or fuel pressure sending unit for an electric gauge. - Page 26 WATER 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.
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Page 27: Section 15
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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