The 1998.5-2002 Cummins got a pretty bad rap over the years for failed VP44 injection pumps, many claiming it was one of the worst decisions ever made to mate this supposed failure-prone pump on a Cummins powered Ram. Now, was it the VP44's fault, or was the engine bay mounted lift pump really the culprit? In most cases, the failure of the low output lift pump causes the demise of the injection pump. And to make matters worse, they continued to use a similar lift pump placement all the way through the 2004.5 model years before going to a higher output in-tank lift pump. So how do you fix one of these trucks for good? Easy, ditch the block mounted/fuel filter mounted stock lift pump and upgrade to an AirDog!
The AirDog II-5G is an all in one premium fuel pump and filtration system for your 1998.5-2004.5 Cummins diesel. This system removes water, particulates, and entrained air from the diesel fuel. The entrained air that is separated from the fuel is returned to the tank through a small return fitting. The fuel is delivered to the engine at the correct pressure and flow rate to meet the demands of the engine under all operating conditions.
The AirDogII-5G DF-220 systems feature a built in adjustable diaphragm pressure regulator. All AirDog II-5G systems include a complete installation kit. The AirDog II-5G, for this particular application, is preset at 17 psi from the factory for a stock application. The regulator is adjustable up to 55 PSI so you can fine tune the system to perfectly match up to your current and future performance upgrades.
California Air Resource Board
D-595-5
The AirDog II-5G is an all in one premium fuel pump and filtration system for your 1998.5-2004.5 Cummins diesel. This system removes water, particulates, and entrained air from the diesel fuel. The entrained air that is separated from the fuel is returned to the tank through a small return fitting. The fuel is delivered to the engine at the correct pressure and flow rate to meet the demands of the engine under all operating conditions.
The AirDogII-5G DF-220 systems feature a built in adjustable diaphragm pressure regulator. All AirDog II-5G systems include a complete installation kit. The AirDog II-5G, for this particular application, is preset at 17 psi from the factory for a stock application. The regulator is adjustable up to 55 PSI so you can fine tune the system to perfectly match up to your current and future performance upgrades.
HOW IT WORKS:
The AirDog II-5G DF- 165 draws fuel from the fuel tank through a 1/2” suction line and the DF-220 draws fuel through a 5/8” suction line to reduce the risk of cavitation at the pump. The fuel is then drawn through the water separator where 92% of water is removed per SAE spec 1488. It is then pressurized through a Gearotor pump and sent to the 2 micron fuel filter before it is sent to the injection pump. The air from aerated fuel, due to tank sloshing and engine return lines, is separated and sent back to the tank through the 3/8” return fitting. The excess fuel that the engine does not use is recirculated through the diaphragm regulator back to the suction side of the pump.
IMPORTANT INFORMATION REGARDING IN-TANK FUEL PUMP:
This specific AirDog unit is designed for trucks featuring the in-tank lift pump. For those unaware, all of the 1998.5-2004.5 Cummins powered Rams came from the factory with a block mounted lift pump. However, if it ever failed and had it replaced previously, it very likely was retrofitted to the newer design that actually placed the pump in the fuel tank. If you're not sure where your pump is located, simply "bump" the key, which will engage the pump, then listen whether the hum from the pump is coming from the engine compartment or the fuel tank.
This specific AirDog unit is designed for trucks featuring the in-tank lift pump. For those unaware, all of the 1998.5-2004.5 Cummins powered Rams came from the factory with a block mounted lift pump. However, if it ever failed and had it replaced previously, it very likely was retrofitted to the newer design that actually placed the pump in the fuel tank. If you're not sure where your pump is located, simply "bump" the key, which will engage the pump, then listen whether the hum from the pump is coming from the engine compartment or the fuel tank.
California Air Resource Board
D-595-5
Specifications
- SkuPF-A7SABD528
- ManufacturerAirDog | PureFlow Technologies
- MPNA7SABD528
KIT CONTENTS:
- (1) AirDog II-5G DF-220
- (1) AirDog II Bracket
- (1) Mounting Hardware Kit
- (1) Frame Bracket
- (1) Wiring Harness
- (1) Bundle of Plastic Ties
- (1) 5/8” High Flow Suction Tube
- (1) Spacer
- (1) 14ft of Fuel Line
- (1) 7ft of 5/8” Fuel Line
- (1) 1/2” Straight Hose Quick Connect Fitting
- (1) 1/2" 90 Degree Hose Quick Connect Fitting
- (1) 3/8” 90 Degree Hose Quick Connect Fitting
- (1) 12mm X 1/2” male SAE J2044 Fitting
- (1) Sealing Washer (installs on WAP102 fitting)
- (1) 1/2” Male J2004 Quick Connect x 3/4-16” UNF
- (1) 3/8” Male J2004 Quick Connect x 7/16” UNF
- (2) 3/4-16 ORB Male to -10 JIC Female Fitting
- (2) -10 JIC Male to 5/8” Barb
- (1) Return Fuel Filler Tube (with 2 Clamps)
- (1) Customer Service Oring Replacement Kit
FEATURES & BENEFITS:
- Supports 800+ horsepower (if you have less horsepower than this, consider an AirDog 100 or 165)
- Flows 220 Gallons Per Hour
- Preset at 17 PSI
- Variable fuel pressure
- 3/4-16 o-ring boss (-8) inlet and outlet ports
- 7/16-20 ORB return port (-4)
- 4 bearing design with intermediate shaft to reduce pump noise and increase reliability
- Low flow fuel return to reduce aeration in the tank
- Demand Flow: only feeds as much fuel as what the engine needs
- Dual feed that feeds fuel to both sides of the Gerotor Pump to decrease cavitation
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Airdog II-5G 220 GPH Air Fuel Separation Lift Pump 98.5-04.5 Dodge 5.9L Cummins W/ In-Tank Pump
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