INSTALLATION MANUAL

#33

6.4L

Ford PowerStroke

2008-2010

MODEL RP-100 & RP-150

With New Quick Connect Components!

PLEASE READ THESE INSTRUCTIONS THOROUGHLY

BEFORE BEGINNING INSTALLATION!

PureFlow AirDog

705 MAUSOLEUM ROAD

SHELBYVILLE, IN 46176 1-877-421-3187

WWW.PUREFLOWAIRDOG.COM

Wire Screen

Insert In Fuel Inlet

To Protect the Gerotor

Fuel Inlet

NOW

On Left Side

Adjustable

Regulator

2

OVERVIEW

Welcome to the Raptor™ Fuel Pump

The Raptor™ Fuel Pump is a Premium replacement lift pump for the Ford

PowerStroke 6.4L diesel engine. A complete installation kit is included.

The 6.4L PowerStroke Diesel Engine is a Common Rail engine and requires

ONLY 8-10 PSI fuel pressure.

The Raptor™ output pressure for the PowerStroke 6.4L diesel engine is factory set at 10 PSI. You may wish to re-adjust the pressure at the time of installation.

Pressure and flows are approximate as they will vary with fuel temperature and as the brushes wear in. Also, pressures will vary with each installation due to the differences in vehicle voltage/amp output and fuel line installation.

The Raptor™ RP-100 is recommended for stock and slightly modified 6.4L

PowerStroke Diesels. The Raptor™ RP-150 is recommended for highly modified

6.4L PowerStroke diesel engine.

The Raptor™, a gerotor fuel pump, features an adjustable pressure regulator and has a protective wire screen insert at the fuel inlet.

PureFlow AirDog Products are Manufactured with a Personal

Touch,

Unsurpassed Attention to Detail and the Most Stringent Quality Assurance!

TYPICAL RAPTOR™ INSTALLATION LAYOUT

Figure 1

NOTE: The pictures used in this manual are for example only and may not be exactly the

same as your truck.

3

QUICK CONNECT COMPONENT OVERVIEW

Provided in this kit is an OE style quick connection system. This system allows 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 blue tabs on the female connector while you firmly pull the assembly apart.

4

Raptor ™ 100 & 150

2008 - 2009 Ford PowerStroke

Section 1 Table of Contents

TABLE OF CONTENTS

Section 1…………………………………….……….….…..Table of Contents

Section 2 ……………………………….……………….…...Safety Guidelines

Section 3……………………………….…………………….….…….Parts List

INSTALLATION PROCEDURES

Section 4 …………………….……….…………Raptor™ & Mounting Brackets

FUEL LINES

Section 5 A………………………………..….……….….....Raptor™ to Engine

Section 5 B.

……………………...………..……….….…Fuel Tank to Raptor™

ELECTRICAL HARNESS

Section 6…..…………………………………..…….……….Electrical Harness

Section 7..………….…………………….……...….…………..Final Check List

5

Raptor™ 100 & 150

2008 - 2010 Ford PowerStroke

Section 2 Installation & Safety Guidelines

Raptor™

MODEL RP-100 & RP-150

The installation of the Raptor™ Fuel Pump can be made relatively easy by following the steps outlined in this manual.

1. Inventory the package components completely. Notify PUREFLOW AIRDOG. immediately of any parts missing or damaged.

2. Read the installation manual and understand how the system operates 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.

NOTE: some of the pictures used in this manual are for example only and may not picture a component exactly the same as found in your truck.

SAFETY GUIDELINES!

CAUTION:

Proper location of the Raptor™ on the vehicle is essential. Consider hazards presented to the equipment by road debris and the elements.

CAUTION:

CAUTION:

Chock the vehicle’s tires to prevent rolling.

CAUTION:

CAUTION:

Disconnect the battery cables to both batteries before proceeding with the

Raptor™ Fuel Pump installation.

Vehicle frame rails should not be drilled into or welded upon.

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 Raptor™!

6

Raptor™ 100 & 150

2008 - 2010 Ford PowerStroke

Section 3 Parts List

QTY DESCRIPTION

1 Installation Manual

1 Raptor™

1 Frame Bracket

1 Wiring Harness

1 Mounting Hardware Kit

1 Bundle of Plastic Ties

1 Spacer

Parts List

Part Number

201-1-0306

RP-100

Or

RP-150

010-3C-0002PC

010-3C-0001PC

5E-2-012

901-61-0102-PM-RP-F

5H-2-1-06/12

010-3C-0003-A-P

IMAGE

1 Suction Hose Assembly

1 Pressure Hose Assembly

1 Customer Service Oring Replacement Kit

2 Push Lock Hose Splice

WAP110-8-8-90

WAP121-8-8

901-05-0100

001-4A-1-0026

2 1/2” Male QC x 3/4-16 ORB

1 Terminal, Spade 1/4"

08J2044-3/4UNF

5D-1-08-A-16/14

7

ILLUSTRATION OF QUICK CONNECT COMPONENTS

8

Raptor™ 100 & 150

2008 - 2010 Ford PowerStroke

Section 4 Raptor™ Fuel Pump & Mounting Brackets

Mounting the Raptor™ to the Truck’s Frame.

The Raptor™ Fuel Pump is best mounted with the electric motor up, as shown.

4-1. Install 1/2” O-ring Boss X 3/4” male fitting (08J2044-3/4UNF) into the Raptor™ port marked “IN”.

FUEL “IN” PORT FUEL “OUT” PORT

Figure 2

4-2. Install 1/2” O-ring Boss X 3/4” male fitting (08J2044-3/4UNF) into the port marked

“OUT”. Properly torque the fitting.

NOTE: Mounting the Raptor™ inside the frame will give more protection from road debris.

Figure 3 Figure 4

4-3. Assemble the Raptor™ to the mounting bracket as shown in Fig. 3. Hold the assembly next to the selected location on the frame to check for clearance . Use the spacer block to clear fuel lines or wiring on the frame, adjust the Raptor™ up or down on the mounting bracket as necessary.

4-4. Loose assemble the mounting bracket and pump assembly to the frame with the backing plate using the 4” x 3/8” bolts, lock washers, and nuts. After positioning the bracket and pump assembly at the selected location, properly torque the fasteners.

9

Raptor™ 100 & 150

2008 - 2010 Ford PowerStroke

Section 5-A Fuel Lines

Raptor 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 5 DISCONNECT HERE Figure 6

View from Front View From Below

5A-2. Insert the female quick connect end (see figure 7) of the

“Pressure Hose Assembly” into the male quick connect fitting previously installed in the port marked “OUT”. You will hear a

“click” when it connects.

Figure 7

5A-3. Connect the other end of the “Pressure Hose Assembly” (Figure 7a) to

The original factory engine supply line shown in figures 5 & 6. It will “click” when properly connected.

Figure 7a

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.

10

Raptor™ 100 & 150

2008 - 2010 Ford PowerStroke

Section 5B Fuel Lines

Fuel Suction Line for the Raptor.

5B-1. Insert the quick connect end (see figure 8) of the “Suction Hose

Assembly” to the male fitting install in the fuel “IN” port during step 4-1 of this manual. A “click” will be heard when the fitting is properly connected.

Figure 8

5B-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 11

Figure 10

Figure 9

Suction Line Return Line

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.

5B-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 11)

5B-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.

11

Raptor™ 100 & 150

2008 - 2010 Ford PowerStroke

Section 6 Electrical Harness

Figure 12

Installing the Raptor™ Fuel Pump wiring harness.

Ground Wire

Hot Lead

The Raptor™ wiring harness.

Water Proof Fuse

Raptor Pump Lead

Figure 13

6-1. To connect the Power Supply Lead to the Raptor™. Insert the 2 pin Deutsch connector on the end of the wiring harness into the corresponding connector on the Raptor™.

Figure 14

6-2. Route the Raptor™ 'activation lead', to the fuse panel on the dash to the left of the steering column. Attach spade connector into a spare fuse holder on the panel that is

“hot” when the starter key is turned to the on position or connect it to the High Pressure

Pump Lead.

6-3. Connect the Black (-) wire to an adequate ground.

Figure 15

BE SURE TO PROPERLY SECURE THE WIRING HARNESS TO THE VEHICLE.

12

Raptor™ 100 & 150

2008 - 2010 Ford PowerStroke

Section 7 Final Check List

INITIAL START PROCEDURE

7-1. Turn the starter key to the on/run position.

7-2. While the Raptor™ Fuel Pump is on, bleed the fuel line to the filter canister by loosening the fuel line connection at the canister. As soon as the line is purged of air and fuel is observed, properly tighten the fuel fitting.

NOTE: put a rag or shop towel over and around the fitting to prevent splatter. Catch all spilled fuel and dispose of properly.

7-3. Start engine!

Adjusting the Pressure Regulator

To adjust the fuel pressure, loosen the lock nut on the regulator adjustment screw. Using a flat blade screw driver, rotate the adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure. Be careful not to loosen the regulator assembly base. If you do, tighten it immediately. When finished, properly torque the regulator adjustment screw lock nut!

Properly tighten the adjustment screw

Lock Nut

when finished.

Figure 16

RECHECK ALL FUEL FITTINGS FOR LEAKAGE AND PROPERLY TORQUE AS

NECESSARY. 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.

13

PUREFLOW AIRDOG

LIFETIME LIMITED EXPRESS WARRANTY

FOR

Covered PureFlow AirDog I, II and Raptor Systems

IMPORTANT NOTICE

TO ACTIVATE YOUR PURFLOW AIRDOG WARRANTY, YOU MUST COMPLETE AND

MAIL YOUR WARRANTY CARD TO PUREFLOW AIRDOG WITH A COPY OF YOUR

ORIGINAL SALES RECEIPT WITHIN 30 DAYS OF PURCHASE. FAILURE TO COMPLETE

AND SUBMIT YOUR WARRANTY CARD WILL RESULT IN A WARRANTY PERIOD OF

THE COVERED PRODUCE TO ONE (1) YEAR FROM THE DATE OF PURCHASE.

PureFlow AirDog (hereafter collectively, “SELLER”) warrants and guarantees only to the Original Purchaser

(hereafter collectively, BUYER) that All PureFlow AirDog Systems (hereafter collectively, PRODUCT) shall be free from defects of materials and workmanship in the manufacturing process for as long as the BUYER owns the

PRODUCT.

The Lifetime Limited Express Warranty is limited to the PRODUCT purchased by the original BUYER of the

PRODUCT and limited solely to the parts contained within the PRODUCT and EXCLUDES ALL ELSE

INCLUDING FILTERS AND WATER SEPARATORS. Any PRODUCT that is in question of Warranty must be returned, shipped prepaid, to PureFlow AirDog. All Warranty claims are subject to the approval of PureFlow

AirDog. If it is determined that a Warranty claim exists, PureFlow AirDog will, at its sole discretion, replace the defective PRODUCT with a comparable PRODUCT, repair the defective PRODUCT, or refund the BUYER”S purchase price in exchange for the PRODUCT. Repairs or replacements are warranted for only the remainder of the original warranty period and only to the original BUYER.

Under no circumstances shall the SELLER be liable for any labor charged or travel time incurred in the diagnosis for defects, removal, or reinstallation of the PRODUCT, or any contingent expense.

Under no circumstances will the SELLER be liable for any damage or expense incurred by reason of the use or sale of the PRODUCT.

Other than expressly set forth herein, the SELLER shall in no way be responsible for the proper or improper use and service of the PRODUCT. In no event shall the SELLER be liable for any special, incidental, indirect or consequential damages of any kind or nature, whether or not the BUYER of the PRODUCT was advised of the possibility of damage or harm, arising or resulting from the use or performance of the PRODUCT and BUYER hereby waives the right to any and all such claims.

BUYER, acknowledges that he/she is not relying on SELLER’S skill or judgment to select or furnish goods suitable for any particular purpose and that SELLER has no liability that will extend beyond the scope of the LIMITED

EXPRESS WARRANTY contained herein, and BUYER hereby waives all remedies or liabilities, expressed or implied, arising by operation of law or otherwise.(including, without limitation, any obligation of SELLER with respect to fitness for any particular purpose; merchantability; and special, incidental, indirect or consequential damages) or whether or not occasioned by SELLER’S negligence.

SELLER disclaims any warranty and expressly disclaims any liability for personal inquiry or damages related to

BUYER’S use of the PRODUCT. BUYER acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this agreement and BUYER agrees to indemnify SELLER and hold SELLER harmless from any claim related to the PRODUCT and its use or performance. Under no circumstances will SELLER be liable for any damages, liabilities, costs or expenses incurred as a result of or by reason of use, performance or sale of the PRODUCT, including without limitation, any damages, liabilities, costs or expenses incurred by reason of

BUYER’S negligence related to those uses of the PRODUCT.

The proper installation of the PRODUCT is the sole responsibility of the BUYER. The SELLER assumes no liability regarding improper installation or misapplication of the PRODUCT.

SELLER hereby provides the following limited warranty as to description, quality, merchantability, fitness for the

PRODUCT’S purpose, productiveness, or any other matter of SELLER’S PRODUCT sold herewith. The SELLER

14

shall be in no way responsible for the open use and service of the PRODUCT and the BUYER hereby waives all rights other than those expressly written herein. This Warranty shall not be extended or varied except by a written instrument signed by SELLER and BUYER.

IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT, THE BUYER MAY

PROMPTLY RETURN THE PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF

OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM THE DATE OF

PURCHASE FOR A FULL REFUND. THE BUYER AGREES THAT THE INSTALLATION OF THIS

PRODUCT CONFIRMS THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND

ACCEPTS THE TERMS AND CONDITIONS OF THIS AGREEMENT.

Warranty Procedure

In the unlikely event a warranty appears as if it may be warranted, the following steps are taken:

1 The customer discussed the symptoms of the problem with a PureFlow AirDog Technician. The customer is to have the system Serial Number and Model Number available for the Technician when the call is made. This will expedite all steps of the process.

2 The customer performs any and all tests requested by the PureFlow AirDog Technician. This is done to isolate the potential problem while eliminating potential installation or maintenance related issues,

3 If the PureFlow AirDog Technician determines based on the customer feedback concerning the requested testing that system may be at fault, the customer is advised that all returned pumps are tested upon arrival and should this returned pump perform at design criteria upon arrival, the customer will be charged a $50.00 fee.

4 The PureFlow AirDog Technician will first request the customer’s phone number in the event the phone call is accidentally disconnected and then transfer the customer to a PureFlow AirDog Customer

Service Representative. Should a Customer Service Representative not be available, the Technician will offer the Customer the option to hold, call back, or receive a return call.

5 The PureFlow AirDog Customer Service Representative will check to determine if the customer’s Warranty

Registration Card is on file. a. If no Warranty Registration is found, the customer will be required to supply the original purchase receipt showing the purchase date. b. If no Warranty Registration is found, the customer will be advised of the options should the system in question is out of the default warranty period (1 year).

6 The PureFlow AirDog Customer Service Representative will request the customer information, including:

Name, Address, Phone Number, Model Number, Serial Number, Year / Make / Model of vehicle,

Name of Dealer purchased from, Purchase Date, Description of Problem, Customers’ understanding of the resolution, and customer credit card information.

7 PureFlow AirDog will cover Ground Shipping charges to ship the replacement unit and will include a prepaid shipping label for the return of the defective unit. Any additional items ordered at the time of the replacement shipment will include their portion of the shipping cost.

8 A period of 15 Calendar Days from the time of shipment is provided for the receipt of the defective unit at the PureFlow AirDog facility. Failure to return ship the defective unit to arrive within the defined time period will result in a charge of $250.00 against the customer’s credit card as the purchase cost of the defective unit.

PFT Bulletin No. 201-1-0306 Revised March 25, 2014

15