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Author Topic: Air Dog II - 150 Install  (Read 4979 times)

Offline i11m10c2

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Air Dog II - 150 Install
« on: September 13, 2009, 05:42:03 am »
Thanks to 04cummins for the assistance with the purchase of our AirDog II.

Tools Required:
18mm deep socket and ratchet
10mm wrench
3/8 wrench
5/16 wrench
5/16 allen wrench
9/16 wrench
flat blade screwdriver
Loctite 2760 (small amount provided in kit but more was needed): insure all threaded fittings are loctited.
Lubricant for barbed ends of all push lock fittings: lubricate all barbed ends of fitting to ease insertion into fuel lines.

First thing to note on the parts list it reads 4 -8 Swivel x 1/2" Push Lock; only 3 are needed.

Disconnected the negative on both batteries

Install connectors to AirDog II
-1/8 x -4 JIC fitting on air/vapor return port (engine side, middle port)
-3/8 NPT x -8 JIC flare fitting on fuel supply port (engine side, right port)
-3/8 NPT x -8 JIC flare fitting on fuel supply port  (tank side)
Use locktite 2760 on all 3 fittings


Attach mounting bracket to frame bracket.
-mounted inside frame rail near transfer case


Decided to pull the bed instead of dropping the tank because of the amount of fuel left in the tank.
-there are 8 18mm bolts holding the bed on

-there is a 10mm ground on the front passenger side
-disconnect the fuel filler neck: use flat blade screw driver to undo band clamp
-disconnect the tail lights
-support the bed and lift


First discrepancy with instructions found once tank was clear. In the fuel filter housing used in the instructions the tank vent is in the top of the housing. Our tank has two vents at either end.


Remove Stock in-tank Fuel Pump Housing
-disconnect wiring for fuel pump
-disconnect fuel return line
-disconnect fuel supply line
There is a specialty tool (9340) to remove the lock ring, a flat blade screw driver and hammer will turn and remove

*take care when removing housing as the cup will be full of fuel*

Found second descrepency with instructions.  The in-tank fuel filter housing shown in instructions has a clear space to drill the 9/16 hole for fuel supply line. Ours had honeycomb re-enforcing; while we could have nibbled it out to make a flat spot for the washers and bulkehead fitting the high chance of damaging the top of the housing made us decide to mount the fuel supply for the AirDog in the tank itself and connect to the fuel supply line to the anchor block.



-disconnect power supply for intank pump, there are two push tabs (front & back) then zip tie out of the way
-the stock fuel supply line will now be used as a vapor return line for the Air Dog so the line needs to be cut above the fitting and zip tied in place
-drill and install anchor block
-when setting the suction tub insure the tab is holding the bottom of the tube off the bottom of the housing


-drilled 9/16 hole in tank

-install -8 JIC 3/8 NPT fitting in bulkhead fitting
-secure in tank with provided washer, gasket, and nut

(really that's not algae in the tank; it's lined and the flash reflected badly. Fuel was a nice clear blueish-yellow color)

Connect Vapor Return Line from Air Dog to Tank
-connect 3/8 quick connect fitting on 1/4 hose for vapor return line
-connect to 1/8 x -4 JIC fitting on air/vapor return port (engine side, middle port)
-size hose to tank and cut excess
-connect 1/4 barb x -4 JIC swivel
-remove the plastic lock (blue) from stock fuel supply on housing

-user provided retaining clip to secure return tube to housing

Connect Fuel Supply Line from Air Dog to Tank
-connect -8 swivel connector to 1/2 fuel line
-connect to 3/8 NPT x -8 JIC flare fitting on fuel supply port  (tank side)
-size hose to tank and cut excess
-connect -8 swivel connector to 1/2 fuel line
-connect to -8 JIC 3/8 NPT fitting in bulkhead fitting


Connect Fuel Supply Line from Air Dog to CP3
-connect -8 swivel 1/2" push lock to 1/2 fuel line
-connect to 3/8 NPT x -8 JIC flare fitting on fuel supply port (engine side, right port)
-size hose to CP3 and cut excess
**Here we had an issue due to our Jacobs Brake Air actuator. The actuator sits above the CP3 and left less than 1 & 1/4" clearance to banjo bolt on CP3. Normal install calls to connect direct to CP3 but because provided 12mm -8 flare fitting and 90 degree -8 swivel did not fit below the air actuator we connected directly to the input on the Fuel Filter canister and left the stock lines from the canister to the CP3. A new fitting will be sourced and fuel line will be moved from fuel filter canister to CP3**


-connect 90 degree -8 Swivel to 1/2 fuel line
-remove banjo bold and original factory fuel supply from the fuel inlet port on CP3
-install 12mm -8 flare fitting with o-ring to CP3
-connect the 90 degree to the 12mm fitting

Wiring Power, EMC Pump Lead
-route wiring harness relay and fuse holder to engine bay. Secure relay to vehicle, no screw provided either remove and use an existing one or use a self taping screw to mount new. Keep power supply red, power supply black, and low fuel pressure leads in engine bay.
-separate orange wire with red stripe from wiring loom at fuel tank.  This is the ecm fuel pump lead, splice in provided female connector.
-connect ECM pump lead on wiring harness
-connect wiring harness power to Air Dog II
-connect power supply red and power supply black to battery

*Prior to attempting to start vehicle pre-fill the water separator.*

Total install time with three sets of hands about 3hr. Most time spent working through issue with the top of the fuel pump housing and removing the bed.
Instructions provided for the wiring harness were right on! The harness made the electrical side of this install very simple.
All provided hardware has great fit and finish.

Initial review of performance with Air Dog II installed is that it pulls through the power band more stably. A bit more haze at WOT.

Offline 04cumminsram

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Re: Air Dog II - 150 Install
« Reply #1 on: September 13, 2009, 06:34:57 am »
sweet write up bud, let me know if you cant find that fitting and i will get one monday and ship it up !  :punk:
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Offline Kilch123

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Re: Air Dog II - 150 Install
« Reply #2 on: September 13, 2009, 01:45:49 pm »
Nice write up Simon!

That install is quite a bit different from the 2nd gen installs...
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Offline noplugs

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Re: Air Dog II - 150 Install
« Reply #3 on: September 13, 2009, 03:48:55 pm »
Very nice. It looks like you did a mod to your intank unit. Dont they also sell a premade so you can just swap it out?

Ok, so how was the raising of the bed, it looks easy as I suspected. Im planning on that route for mine.
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Offline 04cumminsram

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Re: Air Dog II - 150 Install
« Reply #4 on: September 13, 2009, 05:10:09 pm »
All that the one they sell is so you can put the fitting in it and use it as the pickup



the bed offf is the easiest way to go IMO... i did mine by myself with a cherry picker! lol
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Offline lilfroger

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Re: Air Dog II - 150 Install
« Reply #5 on: September 13, 2009, 05:31:38 pm »
Very nice. It looks like you did a mod to your intank unit. Dont they also sell a premade so you can just swap it out?

Ok, so how was the raising of the bed, it looks easy as I suspected. Im planning on that route for mine.


The new 'In-Tank module' is what we used.  It comes with the bits to modify your stock one so you shouldn't have to drill the tank.

We just didn't want to brake the top trying to cut out enough of the honey-comb supports to make a big enough flat spot for the washers.

The cost of the entire unit if they provided a complete new in-tank unit would be HUGE...that thing is an expensive little piece of plastic.

It was nice to lift the bed to do the work.  Meant we knew we had the right length of line and could tie everything up knowing it wasn't going to move when we re-hung the tank.
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