Air Dog II 150 Install

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.

another good informative post . awesome

Great write up. For those of us who are still idiots to the diesel world. What does this do?

Im guessin its a lift pump to help out the stock fuel pump keep up. If your adding this im assuming your no longer on stock tune nor injectors. What all do you have done?

she has a list of stuff done in the intro section , but feel free to post it here as well .

^ my bad Rh lol let me go looking, its nice to see some diesels showing up.

Nope I'm on stock injectors and but have a programmer.

Yes the aftermarket fuel pump do support aftermarket everything. But even a stock rig will see a benefit from it. The stock in-tank pump sits about 7psi, this is 12. At WOT that can drop drastically. While the CP3's aren't nearly as prone to failure as the VP44 due to starvation...it's never a good thing to see fuel pressure drop that low. Lines are also replaced w/larger ones.

And most important for me was the enhanced fuel filterer. The stock fuel / water separator relies on gravity primary and a 7 micro filter. After market's can go as low as 2 micron. Want to keep as much crude and water out of my fuel system.

Does the smarty have a CP program so you can dosome datalogging at WOT? I have seen the Livewire datalogging runs on Duramaxes while we were running and checking to make sure the fuel rails wernt dropping off.

Nope Smarty doesn't have any of that.

Fuel Pressure gauge shows enough to know it's going way to low.

If I find myself in a need for data logging I'll upgrade to the Isspro PERFORMAX gauges.

Nice write up man. My buddy is wanting to do the air dog on his 03 cummins. His lift pump has became pretty weak and doesnt nearly have the power it once had. I'll have to get him to check this out.

lilfrogger is a girl dude. read her sig lol

It's no big deal. I'm pretty used to it


The FASS or Air Dog would be a good option if the lift pump is getting weak. At least it's an 03 and he doesn't have to worry about the VP44. He will have a different pump that that shown in my images though. The 03's and 04's had a Carter push pump at the fuel filter not the intank module.

we're just not used to chicks knowing what they're talking about!! geez woman you put a lot of us dudes to shame! lol

werd^^^ and awesome write up

Yeah i do apologize if i offended you. I didnt read your sig until AF pointed it out.

Offend me?!??! HAHAHAHAHAHHAHHAAHHAA That's almost an impossibility.




Now back on topic.


Replacement filters can of course be purchased from any AirDog vendor or Fleetgaurd filters work:

AirDog 95/150 2 Micron Fuel Filter - FleetGaurd # FF5613

AirDog 95/150 Water Seperator - FleetGaurd # FS19768

Sick write up! I got a 5.9 my self I love it but there's one problem with it....it's all stock ...for now

What kind of performance gains do you get with the air dog?

no perf gains, just helps keep your rail full so it don't fukk up your sticks

good writeup...i've installed one too but that was on a truck w/ a fuel cell in the bed so it was a lot easier

It's more that your preventing performance loss.

The increase in line PSI insures that there is always enough fuel no matter how hard your pushing it.

Also you're removing the air from the fuel for better combustion.

Once larger injectors are installed or a second CP3 is installed a fuel system is a must. For a stock rig it's peace of mind