AirDog II-5G Fuel Air Separation System DF-165 GPH ( A7SABD540)

AirDog II-4G Fuel Air Separation System DF-165 GPH (A6SABD340)

1989-1993 Dodge Cummins 5.9L

NOTE: AIRDOG II DF-165 GPH A5SABD340 HAS BEEN DISCONTINUED AND REPLACED BY AIRDOG II-4G DF-165 GPH A6SABD340

AirDog II-4G DF-165 GPH A6SABD340 1989-1993 Dodge Cummins 5.9L (Preset at 10-13 psi)

The patented AirDog® II-4G has been quality engineered to remove entrained air and water vapor from diesel fuel. The result is a compact, long lasting, efficient, and quiet fuel system made with superior quality for your Dodge Cummins 5.9L.

AirDog II-4G - 4th Generation Fuel System

Advancing the AirDog® Tradition with the 4th Generation Fuel System! The AirDog® II-4G system improves engine performance by:

• Maintaining Correct Injection Timing
• Eliminating Spray Pattern Disruption
• Allowing for a Full Power Stroke and Complete Burn

AirDog II-4G Benefits

• Increased Fuel Economy
• Increased Power Output
• Increased Torque Output
• Longer Injector Life
• Improved Throttle Response
• Reduced Exhaust Emissions
• Optimized Engine Performance
• AirDog® II-4G also overcomes loss of power for diesel engines operating at higher altitudes.

AirDog II-4G Features

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• Dual Feed Gerotor Pump
• Low amperage motor provides efficiency and endurance
• Self-aligning motor requires less maintenance and reduces noise levels
• Intermediate pump shaft seperates motor from fuel
• Small & Compact: ONLY 7″L X 10″T X 3.2″W

AirDog® II-4G Installation Kit

AirDog II-4G Fuel Air Separation Systems Complete Installation Kits include the following, see the installation manual for complete details:

• Relay Control Wiring Harness
• Fuel Module Up-Grade (when required)
• All Fuel Fittings Required
• Mounting Hardware
• 1/2″ Fuel Lines W/ OEM Style Quick Connect Fittings
• AirDog® II-4G Bracket & Spacer
• Plastic Ties
• Installation Manual

AirDog Installation Manual

Click this link to visit the AirDog manufacturer website to view theInstallation Manual

AirDog Replacement Filter Options

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• Replacement AirDog Fuel Filter 2 micron (Part Number FF100-2)
• Replacement AirDog Water Separator (Part Number WS100)

Choose to add one Extra set of Replacement filters (Set: Qty 1 FF100-2 and QTY 1 WS100) from the drop-down menu selection to add the items to your shopping cart. Do I only have to use AirDog® filters? NO. You can cross AirDog® filters over to Napa, Wix, Baldwin, CAT and many others.

AirDog FAQ - Frequently Asked Questions

See FAQ-Frequently Asked Questions page for more information

What pump do I need for my truck?

AirDog® recommends the system most compatible with your current truck. AirDog offers free technical support to help determine the correct system for your current truck.

• Horsepower and AirDog systems - Reference Guide:
• AirDog 100 and AirDog II 100 units are recommended for Stock to 500 Horsepower. (Note: AirDog recommends the AirDog 100 or AirDog II 100 for customers who plan to keep their truck completely stock).
• AirDog 150 and AirDog II-4G 165 units are recommended for 500 Horsepower to 800 Horsepower. (Note: AirDog recommends the AirDog II-4G 165 systems for Modified trucks between 500HP to 800HP).
• AirDog II 200 units are recommended for 800 Horsepower and beyond.

AirDog II Fuel Air Separation System Featuring Demand Flow Technology

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AirDog® II-4G is designed to operate at flows and pressures beyond the maximum requirements of the engine. It receives fuel under vacuum from the fuel tank containing entrained air/vapor, particulate contaminates and unknown quantities of water.

The fuel passes through the water separator which removes the large particulate contaminates that could damage or jam the gerotor fuel pump. The fuel, with only entrained air/vapor and tiny particulate contaminates remaining, then enters the fuel pump.

The fuel, now under positive pressure flow, enters the fuel filter. As the fuel passes through the filter media and the remaining particulate contaminates are caught and contained, the entrained air/vapor is also separated. Through the positive fuel air separation features of the patented AirDog® II-4G the separated air/vapor is discharged from the filter and back to the fuel tank through the Primary Air/Vapor Discharge Port.

The fuel passing through the filter media is now free of contaminates and power robbing air/vapor. At pressures and flows able to meet the needs of the engine, it exits the fuel filter through two passageways. First, the fuel for the engine, passes into the fuel pickup tube and on to the engine. Then, the excess fuel not needed by the engine recycles internally through the pressure regulator back to the water separator.

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Dodge Makes and Models - Cummins Diesel

Arguably the most widely known name in the diesel industry is Cummins. With their pick-up truck engine debut dating back to 1989, they have come quite a long way in perfecting one of the longest lasting engines on the market. Unfortunately, they are also known for having some of the industry’s worst lift pumps.

Starting back in 1989 through 1998, Cummins used a block mounted, cam driven lift pump. These were quite reliable; however, they were just the opposite when it came to priming the system. These pumps were designed to put out 25-30 psi of fuel pressure as well.

From 1998.5-2002, the lift pumps were still on the side of the engine, unfortunately they went away from the cam driven design and decided to go with an electric Carter pump. These pumps primed the system very easily; however they proved to not hold up to the violent vibrations and tortures that the engine put out, thus causing the temperamental VP44 injection pump that it fed to fail prematurely. These pumps were set to put out 12-14 psi to the VP44 injection pump to keep it cool.

From 2003-2004.5 Dodge decided to get away from the engine mounted pump and relocate it to the inlet side of the fuel filter housing. This small black cylindrical pump proved to be a little better than the block mounted version of previous years however they too had their problems. These pumps were set to put out 14-17 psi.

Starting mid-year of 2004, Dodge had a revelation and decided that it would be best to mount the pump in the fuel tank. This not only made it much more difficult to change should there be a problem but it also made it very expensive. While switching to this new design they also discontinued any out-of-tank lift pump replacements. This meant that should your block mounted lift pump go out on your 2001 truck, you would be “updated” to an in-tank pump design. These pumps were also set to put out 14-17 psi.

When it comes time to install of any of these kits, it’s imperative to know that should the truck have an in-tank fuel pump, it will need to be disabled and bypassed. The in-tank pump is not designed to be pulled through. It will cause excessive pressure on the AirDog® or Raptor and could cause it to malfunction.

When it’s time to pull fuel from the tank, there are three ways this is done. The first would be to just hook right to the stock sending unit suction fitting. This is done on all trucks that do not have an in-tank lift pump.