PureFlow AirDog FP-100 User manual

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!
INSTALLATION MANUAL
MODEL FP-100 & FP-150
With New Quick Connect Components!
FORD POWERSTROKE
6.4L DIESEL ENGINE
PLEASE READ THESE INSTRUCTIONS THOROUGHLY
BEFORE BEGINNING INSTALLATION!
PureFlow AirDog
705 MAUSOLEUM ROAD
SHELBYVILLE, IN 46176 1-877-421-3187
www.pureflowairdog.com

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Approved for Sale and Use in California by CARB!
SMALL and COMPACT
7” Long X 3.2” Wide X 10” Tall

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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 6.4L 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.
The AirDog®FP-100 flows 100 GPH and is recommended for stock and slightly
modified PowerStroke Diesels.
The AirDog®FP-150 is recommended for highly modified PowerStroke Diesels.
PureFlow products are manufactured with a personal touch,
unsurpassed attention to detail
and
the most stringent quality control!
TYPICAL INSTALLATION LAYOUT
Figure 1
The AirDog®draws fuel from the fuel tank at a constant flow, removing water, particulates,
and air/vapor while maintaining a regulated pressurized fuel flow to the stock OE high pressure
pump. The air/vapor separated from the fuel by the AirDog®is returned to the fuel tank.
NOTE: The pictures used in this manual are for example only and may not be exactly the
same as your truck.
High Pressure
Fuel Pump

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QUICK CONNECT COMPONENT OVERVIEW
Provided in this kit are two different OE style quick connection systems. These
systems work together to allow for a quick, clean, and professional install.
Jiffy Tite Quick Connect System
Jiffy Tite’s patented quick connect system is used for the connections at the
AirDog® . The images below show the flared formation of the Jiffy Tite System.
Simply insert the male end form into the fitting and push firmly until you hear it
“click” into place. To disconnect the system, use a Jiffy Tite tool similar to the
image below. This tool can be purchased at your local auto parts store. Insert the
tool into the connection and turn it ¼turn to open the retaining spring. While the
retaining spring is open, firmly pull the connection apart.
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 blue tabs on the female connector
while you firmly pull the assembly apart.

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
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…………………….………………….AirDog®& Mounting Brackets
Fuel Lines
Section 5 A……………………………………………..……Fuel To Engine
Section 5 B……………………...……….……..….……Fuel Return to Tank
Section 5 C……………………..……………….….Suction line For FP-100
Section 5 D…………………………………………Suction Line For FP-150
(Includes Hi Flow Suction Tube)
Electrical Harness
Section 6…..…………………………………...…..…….….Electrical Harness
Section 7..………….…………………….……….……….…..Final Check List
Maintenance
Section 8…………………..……………..…Filter Service Recommendations
Section 9…………………..………….…….Cleaning the Gearotor Assembly

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 2 Installation & Safety Guidelines
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. 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.
5. When installing the AirDog® fuel lines be sure to keep the ORIGINAL ENGINE
RETURN LINE connected as it is from the factory!
SAFETY GUIDELINES!
CAUTION! Please be sure to chock the vehicle’s tires to prevent rolling.
CAUTION! Please 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®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.
Use Good Judgment and Common Sense When Installing the AirDog®!

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 3 Parts List
PowerStroke Parts List
QTY
DESCRIPTION
Part Number
IMAGE
1
Installation Manual
ADI-F-100/150
1
AirDog®
FP-100
Or
FP-150
1
AirDog®Mounting Bracket
001-3C-0004
1
Mounting Hardware Kit,
901-61-0102-PM-F
1
Frame Bracket
010-3C-0002PC
010-3C-0001PC
1
Wiring Harness
5E-2-010
1
Return Fuel Filler Tube (with 2 Clamps)
001-4A-1-0150
1
Bundle of Plastic Ties
5H-2-1-06/12
1
High Flow Suction Tube (For FP-150’s Only)
WAP108
1
Grommet (For FP-150’s Only)
5J-1-1-04-0001
1
Spacer
010-3C-0003-A-P
1
Suction Hose Assembly
WAP110-8-8-90
1
Return Hose Assembly
WAP107-8-8
1
Pressure Hose Assembly
WAP121-8-8
1
Customer Service Oring Replacement Kit
901-05-0101
3
Push Lock Hose Splice
001-4A-1-0026
2
½” Female Jiffy Tite Quick Connect x 3/8” NPT
95182

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ILLUSTRATION OF QUICK CONNECT COMPONENTS

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 4 AirDog®& Mounting Brackets
Installing the AirDog®& Mounting Brackets on the Truck’s
Frame!
Figure 2 Figure 3 Figure 4
4-1. 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.
Figure 5 Figure 6 Figure 7
FUEL IN ENGINE
4-2 Install a 3/8” NPT x ½” Jiffy Tite female
quick connect (95182) into the “ENGINE”
and “FUEL IN” ports in the AirDog®.
Figure 8
NOTE: The AirDog® can be mounted on either the inside or the outside of the frame, as
space or personal choice dictates.
Outside the Frame Inside the Frame
Figure 9 Figure 10

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 4 AirDog®& Mounting Brackets
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. Mount the AirDog® so the ‘FUEL IN’
port is directed toward the rear of the vehicle.
Figure 11
Figure 12
4-3. Loose assemble the AirDog® and brackets to the vehicle by clamping the frame
between the mounting plate and back plate with bolts, lock washers, and nuts.
Figure 13
4-4. Position the AirDog® on the frame as necessary, for clearance. Properly torque the
fasteners!

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 5-A Fuel Lines
AirDog®II Fuel Line to the Engine!
5A-1. Disconnect the fuel supply line to the engine from the OE fuel pump. This pump is
located on the driver’s side inside frame rail.
Fuel Pump with 1/2” Quick Connect Fitting
To Engine
Figure 14 DISCONNECT HERE Figure 15
View from Front View From Below
5A-2 Insert the Jiffy Tite male quick connect end (see figure 16) of the “Pressure
Hose Assembly” into the female quick connect fitting previously installed in the port
marked “ENGINE”. You will hear a “click” when it connects.
Figure 16
5A-3. Connect the other end of the “Pressure Hose Assembly” (Figure 17) to
The original factory engine supply line shown in figures 14 & 15. It will “click” when
properly connected.
Figure 17
5A-4 Any excess fuel hose can be addressed by routing the hose in a fashion to take up the
extra length, or a section of the hose can be removed. Push lock splices have been
included if you choose to remove the excess hose.

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 5-B Fuel Lines
Fuel Return Line from the AirDog®to the Tank!
Installing the fuel 'Return to Tank' assembly in Filler Tube
Figure 18
5B-1. Cut filler tube as illustrated, removing 1½inches. Loose assemble clamps on each
end of filler tube.
Figure 19 Figure 20
5B-2. Insert “Return Fuel Filler Tube” assembly in filler tube. INSTALL THE FILLER
TUBE WITH ARROWS POINTING TOWARD THE TANK!! SEE FIG 19
Properly tighten clamps.
5B-3. Insert the Jiffy Tite male quick connect end( see Figure 20) of the “Return Hose
Assembly” into the pre installed female Jiffy Tite fitting in the port marked “Tank”.
The fitting will “click” when properly installed.
5B-4 Attach the other end of the “Return Hose Assembly” onto the male end form of the
“Return Fuel Filler Tube” installed in step 5B-2. A”click” will be heard when the
fitting is properly connected.
5B-5 Any excess fuel hose can be addressed by routing the hose in a fashion to take up
the extra length, or a section of the hose can be removed. Push lock splices have
been included if you choose to remove the excess hose.
Fuel Tank
Hose Clamp
Filler
Tube
Fuel
Return
Fitting

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 5-C Fuel Lines
Section 5-C: Fuel Suction Line for AirDog®FP-100!
NOTE: The AirDog®FP-150 requires a High Flow Suction Tube. If you
are installing an AirDog®FP-150 skip Section 5-C and go to
Section 5D!
5C-1. Insert the male Jiffy Tite quick connect end (see figure 21) of the “Suction Hose
Assembly” to the female Jiffy Tite fitting install in the “Fuel In” port during step 4-3 of
this manual. A “click” will be heard when the fitting is properly connected.
Figure 21
5C-2. Remove the original fuel suction line Quick Connect fitting from fuel tank by squeezing
the tabs on the end of the connector together. Do Not mistake the return line with the
suction line. Consult your factory manual if unsure of these procedures.
Figure 22 Figure 23
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. It may be difficult to
disconnect the fitting it is cocked or becomes cocked during removal.
5C-3. Attach the other end of the “Suction Hose Assembly” to the male quick connect on the
top of the fuel module where the factory suction line was once located. A “click will be
heard when the assembly is properly connected. (Figure 23)
5C-4. Any excess fuel hose can be addressed by routing the hose in a fashion to take up
the extra length, or a section of the hose can be removed. Push lock splices have
been included if you choose to remove the excess hose.
Suction Line

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 5-D Fuel Lines
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 ½suction 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. If you let it rest flat on the floor, the tank may squash out and the suction tube will be
too short after the tank is re-installed in the truck. The suction tube, being cut too short may
suck air as the fuel drops below ¼tank level.
NOTE: Should you choose to pull the pickup bed to access the tank. Be sure to disconnect the
tail light wires, fuel tank filler tube, and any other accessories or components that may be
secured to the frame and bed.
When Dropping the Tank, Always Remember Safety First!
Figure 24
Figure 25
Figure 26
If you choose to remove the bed, properly support the truck bed to prevent
serious injury or death!
Figure 27 Figure 28

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PureFlow AirDog
AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 5-D High Flow Suction Tube
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.
Figure 29
Figure 30
5D-2. Drill a 1-1/8” hole at the selected location in the fuel tank for the suction tube. Hold
a container below the drill point to catch debris.
Figure 31 Figure 32
5D-3. Remove all burrs from the edge of the hole.
Figure 33 Figure 34
5D-4. Install the grommet in the new suction tube access hole.

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 5-D High Flow Suction Tube
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 38.
Figure 35
5D-6. Lubricate the bulkhead fitting with motor oil. Pressing firmly, insert the suction tube
assembly into the grommet. Be sure the bulkhead fitting is completely seated in the
grommet.
Figure 36 Figure 37
5D-7. Re-install the Collection basket.
Re-install the factory return line to the proper
port of the Collection basket before the tank
is fully re-installed.
Figure 38
5D-8. Connect the end of the “Suction Hose Assembly” to the bulk head fitting while it is
easily accessible. A “click” will be heard when it is properly installed.
5D-9 Any excess fuel hose can be addressed by routing the hose in a fashion to take up
the extra length, or a section of the hose can be removed. Push lock splices have
been included if you choose to remove the excess hose

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 5-D High Flow Suction Tube
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.

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 6 Electrical Harness
The AirDog®is equipped with a relay controlled wiring harness.
WIRING DIAGRAM (In Red)
Figure 39
The AirDog®wiring harness!
AirDog® Pump Motor Lead
Pressure Sensor/Switch Lead
Indicator Light Lead
Battery Positive Lead
Battery Negative Lead
Mini Fuse Tap Relay Lead
Figure 43
CAUTION: If the OPTIONAL Low Pressure Indicator Light is not used, be sure to insulate the
two (2) #10 Indicator Light connectors to prevent accidental contact.
Securing the Relay and Fuse Holder to the Vehicle
6-1. Secure the relay and fuse holder to the vehicle.
Figure 40 Figure 41
High Pressure
Fuel Pump

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 6 Electrical Harness
Connecting the AirDog®Relay Control Lead
Figure 42
6-3. 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.
NOTE: The power supply leads can be connected to the battery or the
alternator. Connecting the power supply leads to the alternator
instead of the battery will create a corrosion free connection.
Black (-) Red (+)
6-4. Route the power supply leads to the alternator.
Connect the Black (-) lead to the alternator
Ground connection.
Connect the Red (+) lead to the alternator Hot
Lead going to the battery.
Figure 43
OR
6-5. Should you choose to connect the power
supply leads directly to the battery, connect
the RED (+) lead to the POSITIVE (+) post
of the driver's side battery. Connect the
BLACK (-) lead to the NEGATIVE (-) post
of the same battery.
Figure 44
6-6. Route the wiring harness to the AirDog®
and connect the 2 pin Deutsch connector
to the corresponding connector on
the AirDog®.
Figure 45

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AirDog®FP-100 & FP-150 Ford PowerStroke 2008 6.4L
Section 7 Initial Startup Procedures
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. While the AirDog®is operating, bleed the fuel line to the engine of air by loosening the
fuel line connection at the engine fitting. As soon as the line is purged of air and pure
fuel is observed, properly tighten the fuel fitting. NOTE: put a rag or shop towel over
and around fitting to prevent splatter. Catch all spilled fuel and dispose of properly.
7-4. Start engine!
RECHECK ALL FUEL FITTINGS FOR LEAKAGE AND PROPERLY TORQUE. BE
SURE ALL FUEL LINES ARE PROPERLY ROUTED TO PROTECT FROM
EXCESSIVE HEAT AND SECURED TO PROTECT FROM CHAFFING AND
ABRASION. RECHECK ALL ELECTRICAL LINES, SECURE AS NECESSARY.
Checking Pump Noise!
Note: Each AirDog®has been manufactured in a Quality Controlled process and wet tested for
operation and performance before shipment. This is a very quiet and smooth running system.
With fuel or air alone, the AirDog® fuel pump will run very quietly. However, if any fuel
fitting on the vacuum side, between the fuel tank and the AirDog®or the water separator, has
been left loose during the installation process, the system may suck air at an excessive rate and
will be very noisy. To check for this problem, unscrew the water separator 3 or 4 full turns and
activate the AirDog®by turning the ignition switch to on. If the AirDog® runs quietly, then
excessive air from a loose fitting or leaking water separator seal is most likely the reason for
the excessive noise. Correct as necessary.
A. The seal groove in the 3” filter is a snug fit and on occasion the seal has been found
to not be fully seated. Remove the water separator, remove the seal from the top of
the nut plate. Clean and lubricate the seal grove. Carefully replace the seal in the
grove. Be sure to fully seat the seal.
B. Check all fittings, especially the quick connect at the tank.