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Summary of Contents for Airdog II DF-165
- Page 1 PureFlow AirDog® AirDog® II-5G DF-165 1999-2003 7.3L Ford 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 1999-2003 Ford 7.3L Powerstroke SMALL and COMPACT 7” Long X 3.2” Wide X 10” Tall...
- Page 3 Thank you for your purchase and welcome to PureFlow AirDog’s AirDog®II-5G fuel air separation and delivery system for the 1999-2003 7.3L. The AirDog®II-5G is an all in one premium fuel pump and filtration system for the 7.3L. This system removes water, particulates, and entrained air from the diesel fuel. The entrained air that is separated from the fuel is returned to the tank through a small return fitting.
- Page 4 PureFlow AirDog® AirDog® II-5G DF-165 1999-2003 Ford 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.
- Page 5 PureFlow AirDog® AirDog® II-5G DF-165 1999-2003 7.3L Ford 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, Brackets, and Mounting Fuel Lines Section 5………………………………………..…………Fuel Line Assembly Section 6A……………………….…..……..….…Supply Line to Engine...
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Page 6: Safety Guidelines
3. The installation recommendations contained herein are suggested installation guidelines only. Individual installations may vary. 4. When installing the AirDog®II-5G fuel lines, be sure to connect the ORIGINAL ENGINE RETURN LINE to the fuel tank as it was from the factory when the installation is complete! If any installation procedure is uncertain, contact PUREFLOW AIRDOG for technical assistance. - Page 7 PureFlow AirDog® AirDog® II DF-165 1999-2003 7.3L Ford Powerstroke Section 3 Parts List Powerstroke Parts List DESCRIPTION PART NUMBER IMAGE ® AirDog II-5G DF-165 ® AirDog II Mounting Bracket 001-3C-0004 Mounting Hardware Kit, 901-61-0102-PM-F 010-3C-0002 Frame Bracket 010-3C-0001 Wiring Harness...
- Page 8 PureFlow AirDog® AirDog® II DF-165 1999-2003 7.3L Ford Powerstroke ILLUSTRATION OF QUICK CONNECT COMPONENTS...
- Page 9 Dip the threaded end of the 06J2044716UNF fitting into clean motor oil and hand- thread into the “RETURN” port of the the AirDog®II-5G filter base as illustrated in figures 1 and 2. Using a 9/16” deep socket, torque the fitting to 84in-lb or 7ft-lb.
- Page 10 The photos in this manual may not be the same as your application. 4-5. Be sure to tuck the AirDog®II-5G as far up as possible without it rubbing on anything to prevent damage from road debris. The bracket assembly is adjustible to achieve this.
- Page 11 Fittings, Brackets, and Mounting 4-6. Clamp the frame between the AirDog® bracket assembly and the backing plate (figure 8) using the 3/8” bolts, lock washers, and nuts included in the kit. You will need two 9/16” wrenches. Properly torque all fastners! BE SURE to mount the AirDog®II-5G with the “INLET”...
- Page 12 Figure 10 Figure 11 5-2. Now plug that fuel line with that fitting into the connection on the either the AirDog or the truck where the manual calls it out. 5-3. Run the fuel line along the frame away from any hot or moving parts such as exhaust or the driveshaft (Figure 12).
- Page 13 6A-3. Run the other end of the fuel line along the frame, away from any hot or moving parts, to the port in the AirDog base labeled “Engine.” Cut the fuel line to length and press in fuel line end FQC12S per section 5. Once the connector is pressed in, press it onto the male connector in the filter base in the “Engine”...
- Page 14 6B-3. Assemble one end of the hose (Reference section 5) using Fuel line end FQC3890 and plug it into the “Return” J2044 fitting installed in the AirDog® (Figure 20). A “click” will be heard once the fitting is properly connected.
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Page 15: In More Detail
HS20 Figure 24 6C-3. Run the fuel line along the frame as mentioned in step 5-3 to the AirDog® “Fuel In” port. Cut the fuel line to length and insert fuel line end FQC12S per step 5-1. Once the fuel line end is pressed in, connect it to the male J2044 fitting in the AirDog® “Fuel In”... -
Page 16: Wiring Diagram
PureFlow AirDog® AirDog® II-5G DF-165 1999-2003 7.3L Ford Powerstroke Section 7 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 27 Secure the Relay and Fuse Holder to the Vehicle 7-1. - Page 17 Figure 29 Figure 30 ® OR if you prefer, 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 (Figure 30).
- Page 18 ® ® activate the AirDog II by turning the ignition switch to on If the AirDog II runs quietly, then excessive air from a loose fitting or leaking pre-filter seal or vapor from fuel flow restriction is most likely the reason for the excessive noise. Correct as necessary.
- Page 19 It is suggested to check/drain the water separator every three months or as needed should you experience excessive ‘water in fuel’ conditions. When installing the water separator, be sure to clean the underside of the AirDog® base. Follow the instructions printed on the pre-filter for proper tightening procedures.
- Page 20 Be very careful not to dislodge screws. Torque the cap screws in or pinch the O-rings. an opposing pattern. If there is damaged found to either the Gerotor, Gerotor pocket, or O-rings, call into AirDog® Tech Support for further assistance.
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Page 21: Pressure Adjustment
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 22: Water Separator
PureFlow AirDog® AirDog® II-5G DF-165 1999-2003 7.3L Ford Powerstroke 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 23 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 24: Warranty Procedure
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...
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