Airdog II DF-165 User manual

PureFlow AirDog®
AirDog® II-5G DF-165 1999-2003 7.3L Ford Powerstroke
PROTECTED BY
CANADIAN PATENT US PATENTS AUSTRALIAN PATENT
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NEW ZEALAND PATENT
532356
Additional Foreign Patents Pending in Europe, South America, Mexico, Japan, and China!
#58

PureFlow AirDog®
AirDog® II-5G DF-165 1999-2003 Ford 7.3L Powerstroke
2
SMALL and COMPACT
7” Long X 3.2” Wide X 10” Tall

PureFlow AirDog®
AirDog® II-5G DF-165 1999-2003 Ford Powerstroke
3
OVERVIEW
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. The fuel is delivered to the engine at the correct pressure and flow rate to meet the
demands of the engine under all operating conditions.
The AirDog®II-5G DF-165 systems feature a built in adjustible diaphragm pressure
regulator. All AirDog®II-5G systems include a complete installation kit.
The AirDog®II-5G, for this particular application, is preset at 55-60psi from factory for
a stock application. The regulator is adjustible up to 70 psi for fine tuning the system for
performance upgrades. WARNING: RUNNING THE PUMP ABOVE 70PSI WILL DECREASE THE
LIFE OF THE PUMP SIGNIFICANTLY AND MAY VOID THE WARRANTY.
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.
HOW THE 5G OPERATES
The AirDog®II-5G DF-165 draws fuel from the fuel tank. The fuel is then drawn through the
water separator where 92% of water is removed per SAE spec 1488. It is then pressurized
through a Gerotor pump and sent to the 2 micron fuel filter before it is sent to the injection
pump. The air from aerated fuel, due to tank sloshing and engine return lines, is separated
and sent back to the tank through the 3/8” return fitting. The excess fuel that the engine
does not use is recirculated through the diaphragm regulator back to the suction side of the
pump.

PureFlow AirDog®
AirDog® II-5G DF-165 1999-2003 Ford Powerstroke
4
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. 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. Push firmly until you hear it “click” into place. To
disconnect the fittings, press down and hold the tabs on the female connector
while you firmly pull the assembly apart.

PureFlow AirDog®
AirDog® II-5G DF-165 1999-2003 7.3L Ford Powerstroke
Section 1 Table of Contents
5
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
Section 6B…………………….......…….........................Return Line to Tank
Section 6C…………………….……...…………...….Suction Line from Tank
Electrical Harness
Section 7…..……………………………….…...…...…..……..Wiring Harness
Section 8..………….………………….………..……Initial Startup Procedure
Maintenance
Section 9………………….………….....…Filter Service Recommendations
Section 10……………..………..…………...Cleaning the Gerotor Assembly
Section 11…………………………………. Pressure Regulator Adjustment
Section 12…………………………………………………..Filter Maintenance
Section13………………………………………………....Warranty Procedure

PureFlow AirDog®
AirDog® II-5G DF-165 1999-2003 7.3L Ford Powerstroke
Section 2 Installation and Safety Guidelines
6
AirDog®II-5G MODEL DF-165
INSTALLATION GUIDELINES
The installation of your AirDog®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.
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.
SAFETY GUIDELINES!
CAUTION! Be sure to chock the vehicle’s tires to prevent rolling.
CAUTION! Use proper supports when working beneath an elevated vehicle.
CAUTION! Most diesel pickups have two (2) 12volt batteries. Disconnect the battery
cables to both batteries before proceeding with the AirDog®II-5G installation.
CAUTION! Vehicle frame rails should not be drilled into or welded upon.
CAUTION! Wear safety glasses when operating power tools such as drills and grinders or
when using a punch or chisel.
CAUTION! Use common sense when routing fuel lines and electrical harnesses. Keep
them away from hot exhaust components and/or moving parts. Properly
secure lines to prevent chaffing.
NOTE: The pictures used in this manual are for example only and may not be exactly the
same as your truck.

PureFlow AirDog®
AirDog® II DF-165 1999-2003 7.3L Ford Powerstroke
Section 3 Parts List
7
Powerstroke Parts List
QTY
DESCRIPTION
PART NUMBER
IMAGE
1
AirDog®II-5G
DF-165
1
AirDog®II Mounting Bracket
001-3C-0004
1
Mounting Hardware Kit,
901-61-0102-PM-F
1
Frame Bracket
010-3C-0002
010-3C-0001
1
Wiring Harness
5E-2-010-HD
1
Return Fuel Filler Tube (with 2 Clamps)
001-4A-1-0150
1
Bundle of Plastic Ties
5H-2-1-06/12
1
Spacer
010-3C-0003-A-P
1
20ft of Fuel Line
HS20
1
5/16” male J2044 Quick Connect to 1/2” Push Lock Fitting
MQC516
3
1/2” Straight Hose Quick Connect Fitting
FQC12S
2
3/8” 90° Hose Quick Connect Fitting
FQC3890
2
1/2” Male J2004 Quick Connect x 3/4-16” UNF
08J2044-3/4UNF
1
3/8” Male J2004 Quick Connect x 7/16” UNF
06J2044716UNF
1
Customer Service O-ring Replacement Kit
901-05-0100
N/A

PureFlow AirDog®
AirDog® II DF-165 1999-2003 7.3L Ford Powerstroke
8
ILLUSTRATION OF QUICK CONNECT COMPONENTS

PureFlow AirDog®
AirDog® II DF-165 1999-2003 7.3L Ford Powerstroke
Section 4 Fittings, Brackets, and Mounting
9
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. Using a 3/4” deep socket, torque the fittings to 180in-
lb or 15ft-lb. DO NOT overtighten the fittings or damage may occur!
4-2 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. DO
NOT overtighten the fittings or damage may occur!
Figure 1
Figure 2
Figure 3
RETURN
ENGINE
INLET

PureFlow AirDog®
AirDog® II-5G DF-165 1999-2003 7.3L Ford Powerstroke
Section 4 (Continued) Fittings, Brackets, and Mounting
10
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).
Properly torque all fasteners! You will need a 3/16” allen and a 1/2" wrench. The
bracket assembly should look like figure 6.
4-4. Attach the AirDog®II-5G to the frame bracket assembly as shown in figure 7 using the
supplied hardware in the mounting bracket hardware kit. The brackets are universal
and can be mounted anywhere there is room.
NOTE: We recommend installing the AirDog® on the inside of the frame rail, but we
understand some applications just don’t have the room. 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.
Figure 4
Figure 5
Figure 6
Figure 7