PureFlow AirDog AirDog II DF-100 User manual

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!
#19

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
2
SMALL and COMPACT
7” Long X 3.2” Wide X 10” Tall

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
3
OVERVIEW
Welcome to PureFlow®AirDog®
Fuel Air Separation, Filtration and Delivery System for the Diesel Engine
The AirDog®II Fuel Preporator® is a premium fuel pump and complete filtration system for the
Duramax Diesel Engine. The system removes water, particulates, and entrained air from the
fuel. The entrained air separated from the fuel is returned to the tank through a small return
line. The fuel is then delivered to the engine at the correct pressure to meet the demands of
the engine under all operating conditions.
The AirDog®II-4G systems feature a built in adjustible pressure regulator. All AirDog®II
and AirDog®II-4G systems include a complete installation kit.
The AirDog®II-4G for this particular application are preset at 8-10psi from factory for a
stock application. The regulator is adjustible for fine tuning the system for performance
upgrades. WARNING: RUNNING THE PUMP ABOVE 75PSI FOR THE 100 AND 165 AND ABOVE
30PSI FOR THE 200 WILL DECREASE THE LIFE OF THE PUMP SIGNIFICANTLY AND MAY VOID THE
WARRANTY.
The AirDog®II DF-100 is recommended for stock and slightly modified Duramax Diesels.
The AirDog®II DF-165 is recommended for highly modified Duramax Diesels.
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
TYPICAL INSTALLATION LAYOUT
The AirDog®II draws fuel from the fuel tank, removing water, particulates, and air/vapor. A
regulated pressurized flow is maintained to meet the engine’s varying fuel demands. The
separated air/vapor 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.
Fuel Supply Line
Fuel Module

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
4
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. 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 DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 1 Table of Contents
5
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
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
Section 13……………………………………………….….Warranty Procedure

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 2 Installation and Safety Guidelines
6
AirDog® II
The installation of your AirDog®II 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 II 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®!

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 3 Parts List
7
AirDog®II Parts List
QTY
DESCRIPTION
PART NUMBER
IMAGE
1
AirDog®II
DF-100
DF-165
DF-200
1
AirDog®II Mounting Bracket
001-3C-0004
1
Mounting Hardware Kit,
901-61-0102-PM-C
1
Frame Bracket Set
010-3C-0002
010-3C-0001
1
Wiring Harness
5E-2-010
1
Bundle of Plastic Ties
5H-2-1-06/12
1
Spacer
010-3C-0003-A-P
1
20ft of Hose
HS20
5
1/2” Straight Hose Quick Connect End
FQC12S
1
3/8” 90° Hose Quick Connect Fitting
FQC3890
1
Customer Service Oring Replacement Kit
901-05-0100
2
1/2” Male J2004 Quick Connect x 9/16” UNF
08J2044916UNF
1
3/8” Male J2004 Quick Connect x 5/16” UNF
06J2044516UNF
1
Return Fuel Filler Tube (with 2 Clamps)
001-4A-1-0200

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
8
ILLUSTRATION OF QUICK CONNECT COMPONENTS

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 4 Fittings, Brackets, and Mounting
9
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” and
“FUEL IN” ports of the AirDog®II-4G filter base as illustrated in figures 1, 2, and 3. Using
a 3/4” deep socket, torque the fittings to 120in-lb or 10ft-lb. DO NOT overtighten the
fittings or damage may occur!
4-2. Dip the threaded end of the 3/8” male J2044 quick connect X 5/16” UNF
(06J2044516UNF) fitting into clean motor oil and hand-thread into the return port of the
the AirDog®II-4G filter base as illustrated in figures 1 and 4. Using a 5/8” deep socket,
torque the fitting to 60in-lb or 5ft-lb. DO NOT overtighten the fittings or damage may
occur!
Figure 1
Figure 2
Figure 3
RETURN
ENGINE
FUEL IN
Figure 4
RETURN
ENGINE

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
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 5 using the four bolts, lock
washers, and nuts included in the mounting bracket hardware kit (figure 6). Properly
torque all fasteners! You will need a 3/16” allen and a 1/2" wrench. The bracket
assembly should look like figure 7.
4-4. Attach the AirDog®II-4G to the frame bracket assembly as shown in figure 8 using the
supplied hardware in the mounting bracket hardware kit.
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-4G as far up as possible without it rubbing on anything to
prevent damage from road debris. The braket assembly is adjustible to achieve this.
Figure 5
Figure 6
Figure 7
Figure 8

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 4 (Continued) Fittings, Brackets, and Mounting
11
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”
wrenches. Properly torque all fastners! BE SURE to mount the AirDog®II with the “FUEL
IN” port toward the rear of the vehicle (Figure 10).
Figure 9
Figure10
VEHICLE
FRONT
VEHICLE
REAR
FUEL IN

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 5 Fuel Line Assembly
12
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.
You won’t want to pre-assemble the hoses or your lengths may be off.
5-1. Take the fuel line end and lubricate the barbed end with clean motor oil (Figure 11) and
press it into the fuel line (HS20) until all three barbs are covered (Figures 12 and 13). The
fuel line end should look like Figure 15.
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 14). Cut the hose to length and insert the other fuel line end that
the manual calls out into the fuel line as outlined in step 5-1.
NOTE: Hose clamps are not needed for these push-lock connectors.
Figure 11
Figure 13
Figure 12
Figure 14

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 6A Fuel Lines (Supply Line to Engine)
13
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). It will be the larger of the two lines that are on the frame.
NOTE: The fuel tank connections are located behind the tank shield. It may be necessary to
remove or bend the tank shield down to access the suction tube quick connect fitting.
6A-1. Remove the factory fuel supply line from the fuel tank suction tube. Place the 1/2”
fuel line disconnect tool around the fuel line and press into the Quick Connect fitting
to release the locks. Carefully pull the factory quick connect fitting and fuel line from
the fuel tank suction fitting.
The DISCONNECT TOOL (as seen below) can be purchased from your local auto parts store. This
tool is NOT included in the kit.
6A-2. Disconnect the other end of the fuel supply line from the steel line using the disconnect
tool. It is the larger of the two lines on the frame. This connection is located between
the frame bracket and the front of the fuel tank. You may now remove the 18” of
factory flex line.
Figure 15
Figure 16
Figure 17

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 6A (Continued) Fuel Lines (Supply Line to Engine)
14
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. A “click” will be
heard once properly connected.
6A-4. Run the fuel line along the frame as mentioned in step 5-3 to the “Engine” port in the
AirDog®. Cut the fuel line to length and insert fuel line end FQC12S per step 5-1. Once
the connector is installed, connect it to the male J2044 fitting in the “Engine” port in the
AirDog®. A “click” will be heard once properly connected.
CAUTION: Properly secure all fuel lines to prevent damage from chaffing and/or abrasion.
FQC12S
HS20
Figure 18
FQC12S
HS20
Figure 19

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 6B Fuel Lines (Return Line to Tank)
15
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 ½inch of hose. Loose assemble
clamps on each end of filler tube before the filler tube is pushed in.
6B-2. Insert the “Return Fuel Filler Tube” assembly (P/N 001-4A-1-0200) in the filler tube.
INSTALL THE FILLER TUBE WITH ARROWS, WHICH ARE STAMPED IN THE PART,
POINTING TOWARD THE TANK!! SEE FIG 21. Properly tighten clamps.
NOTE: Some 01-04 trucks have a plastic tube inside of the fill tube, be sure NOT to cut this clear tube.
You will need to only cut the outer rubber hose then slide the plastic tube inside the return fill tube
supplied in the kit, then clamp the rubber fill tube onto the adapter as shown in figure 22.
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 23). A “click” will
be heard once the fitting is properly connected.
6B-4. Run the fuel line along the frame as mentioned in step 5-3 to the filler neck tee. Cut the
fuel line to length and insert fuel line end FQC12S per step 5-1. Once the connector is
installed, connect it to the male J2044 fitting in the filler neck tee (001-4A-1-0200). A
“click” will be heard once properly connected.
HS20
Fuel Tank
Hose Clamp
Filler
Tube
Fuel
Return
Fitting
Figure 20
Figure 22
Figure 21
Towards
Tank
Figure 23
FQC3890
HS20
FQC12S
HS20
Figure 24

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 6C Fuel Lines (Suction Line from Tank)
16
Fuel Suction Line for AirDog®II
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® labled “Fuel In.” A “click” will be heard
once properly connected.
6C-2. It may be necessary to remove or bend the metal fuel tank shield (Figure 23) to gain
access to the fuel tank suction line connection.
6C-3. Assemble one end of the hose (Reference section 5) using fuel line end FCQ12S and plug
it into the male connection to where the factory suction line was just removed in step
6A-1. A “click” will be heard once properly connected.
FQC12S
HS20
Figure 25
Fuel Tank Shield
Figure 26
FQC12S
HS20
Figure 27

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 7 Wiring Harness
17
AirDog®Wiring Harness Install
WIRING DIAGRAM
CAUTION: If the OPTIONAL Low Pressure Indicator Light is not used, be sure to insulate the two
(2) #10 Indicator Light connectors and pressure sensor lead to prevent accidental contact.
*The light kit is sold separately and is not included in this kit.
Secure the Relay and Fuse Holder to the Vehicle
7-1. Secure the relay and fuse holder to the vehicle. Be sure to rout the wires away from any
moving parts. The relay is illustrated below in figure 29. The fuse holder mounting is the
same concept.
MINI-TAP RELAY
TRIGGER LEAD
INDICATOR
LIGHT LEADS
AirDog®
MOTOR LEAD
PRESSURE
SWITCH
LEAD*
BATTERY
NEGATIVE LEAD
BATTERY
POSITIVE LEAD
FUSE HOLDER
WITH 20A FUSE
RELAY
Figure 28
Figure 29

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 7 (Continued) Wiring Harness
18
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. After accessing the fuse panel, use a test light or voltmeter to find a fuse terminal that is
HOT only when the ignition is in the on position. Connect the ‘Red’ Relay Trigger wire
with the mini fuse tap to that terminal. Be sure to install the fuse that is removed back
into the fuse tap we supply, once installed into the fuse box the fuse tap should have
both fuse spots filled. TBC Batt, Ign 1 or 2, Acc and HVAC are commonly used to supply
power.
Relay
Trigger Lead
Connection
Connecting the Power Supply Leads to the Alternator or Battery
Note: Connecting the power supply leads to the alternator instead of the battery will create a
corrosion resistant connection.
7-3A. Route the Red and Black power supply leads to the alternator. Connect the Black (-) lead
to the alternator Chassis Ground connection. Connect the Red (+) lead to the alternator
Hot Lead going to the battery.
Figure 31
Figure 30
Black (-)
Red (+)
Replace the Protective Cover
Figure 32
Figure 33

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 7 (Continued) Wiring Harness
19
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.
7-4. Route the wiring harness to the AirDog®and connect the 2 pin Deutsch connector to the
corresponding connector on the AirDog®.
NOTE: If the Optional Indicator Light is not used, secure the pressure switch lead to the
wiring harness with a plastic tie. Also, cover the pressure sensor lead to protect it, you may
want to use it later.
Red (+)
Black (-)
Figure 34
Figure 35

PureFlow AirDog®
AirDog® II DF-100, DF-165, & DF-200 2001-2010 Duramax Diesel
Section 8 Initial Startup Procedure
20
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.
8-2. Rub diesel fuel or oil on the filter seals before installing to ensure a proper seal.
8-3. Turn the starter key to the on/run position.
8-4. While the AirDog®II 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.
Wear safety glasses.
8-5. 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 FOR EXCESSIVE PUMP NOISE
NOTE: Each AirDog®II has been manufactured in a Quality Controlled process and wet tested for
operation and performance before shipment. This is a smooth running system. With fuel or air
alone, the AirDog®II fuel pump will run quietly. However, if any fuel fitting on the vacuum side,
between the fuel tank and the AirDog®II or the pre-filter has been left loose during the
installation process, the system may be sucking air at an excessive rate and will be very noisy.
Excessive restriction in the suction line from the fuel tank can cause vapor and noise, as well. To
check for these problems, unscrew the pre-filter 3 or 4 full turns and 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.
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 pre-filter, 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.