Just got my truck back last night from the trans guy. It needs to be timed and tuned, but otherwise he said it's in great shape. Only problem found were the fuel lines. they are all corroded badly and need to be replaced. they are pricey from Dodge, sounds like for a little more $$$ I can buy the FASS system, any real difference on my truck? Plans for the near future are pump work, timing, bigger turbo, possible inj. looking for 400hp to use for towing.

 

Send a PM to user name Hammer, Andy (Hammer) has a FASS on his 12v. I am sure he would be happy to answer any questions you might have.

 

I just put an AirDog100 on my 97. I have to say I think it is some of the best money I have spent.
My fuel system now consists of fuel tank, to AirDog, to injection pump (P7100), to injector, back to tank.
I have eliminated all of the stock junk. I see a consistent 30psi at idle and 28-30psi at WOT. This is with a 62mm turbo and DDP4s with a 0 plate..

One of the best parts about it is the ease of filter changes. It literally takes 2 minutes to change a filter now.
I also like having the 3 micron filters. You can also get the replacements from Cummins for $9.00 a piece.
Also, the truck starts 100 times better now in the cold.

Pure Flow Technologies (AirDog) was th original Air/Fuel seperation pump. It was Charlie Ekstram who invented it. His son Brad Ekstram split from his dad and started FASS. Either way, you are getting virtually the same thing. AirDog is a more compact unit, and I have read they have a far better pump on it.
Pure Flow Technologies (AirDog) has a special going on for $499 for the whole kit. Call them up and talk to Joe or Charlie.

Also, If you wanted to go cheap, you can get 15' of 3/8" and 5/16" diesel rated hose, and replace the lines from the tank to the filter on the supply and from the tank to the overflow return line on the return.
You are just eliminating the steel lines. Alot of members, including myself have done this (I just wanted an electric pump) to remedy the rotted lines.
www.Vulcanperformance.com has Parker diesel hose the cheapest. You will also need some hose clamps.

 

Dieselman,

In the Airdog instructions, it looks as though you continue to use the stock fuel filter housing as a junction point for the return lines. What did you use to eliminate that stuff?

Thanks,

Craig

 

Heres some pics, Not the best though.
1st pic is the injector return line. I used a 3/16" comp. x 1/8" male thread. I then used a 1/8"x3/8" reducing coupling with a 3/8" male thread x 5/16" barb fitting.

2nd pic is the overflow valve return line. I used a 5/16" compression x 3/8" male thread. I then put a 3/8" coupling on that and then a 3/8" x 5/16" barbed fitting.

3rd pic. is the return line tee. Its a 3/8" brass tee with 3-3/8" male thread x 5/16" barbed fittings.

Both the injector return line and the overflow return line go int the tee and then it goes back to the tank.

I bought all the brass fittings from Menards. The 5/16" diesel rated hose I got from vulcan performance.

I talked to Toby at pure flow, and he said if I wanted to get rid of all the stock stuff, it would be just fine to do it this way.


Hoped this helped.
Tony

 

Tony,

That rocks! It's exactly what I wanted to do - eliminate as much useless factory stuff as possible. I was a little disappointed to see the kit was going to use the factory filter. One other question, since I'm ordering fittings, what size are the fittings on the top of the fuel tank? I want to have some of those just in case.

It looks like the Airdog kit comes with enough line to replace all of the supply line. So hopefully that side shouldn't be an issue.

Thanks alot, I appreciate you saving me some time and aggravation.

- Craig

 

I just used a 5/16 compression x 3/8" male thread, 3/8" coupling, and a 3/8" male thread to a 5/16" barbed fitting.
I just tied into the steel lines on the frame just before the tank.
My steel fuel lines are fine.

The reason I used 3/8" thread fittings on everything is, if you look at the fittings, by the time you thread everything together, 3/8" seemed to not contract any of the 5/16" size (if that makes sense).

Also, 3/8" is more common than 5/16".

The hardest fitting to find is the 3/16" compression x whatever to 3/8".

If you dont have a Menards, a plumbing supply house will have it.

 

Thanks again Tony. I think I'm going to go all the way to the tank, my lines are a little crusty with 200k on them.

Anybody know the fitting sizes?