Installation of an AirDog or Fass Fuel system part 1
 

This is Part one of two of the AirDog fuel system installation

This article is to help folks install their aftermarket fuel systems. This includes removing the stock fuel lift pumps, bypassing filters, and installing new plumbing.
This Installation shown is for a 1998.5 to 2001 Dodge 2 Gen Truck, but the techniques can be applied to any type of vehicle.

The first thing is to find a suitable place to mount the pump. Inside the frame rail is the safest in my opinion, because it is protected from impact if involved in an accident.


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Next the location you pick should be as close to the fuel tank as possible because this pump is using suction through a large draw straw to pull fuel out of the tank.(the closer you are to the tank the less it has to work).This also reduces the amount of hose required for the job.


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There are two ways to access the fuel tank either pull the bed bolts and lift it or drop the fuel tank. This Post is with the fuel tank dropped.
De-fuel tank first then support tank with a stand remove the two strap bolts with a long extension and socket.


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Open the fuel filler door and remove the 3 screws from the filler neck flange, or just disconnect the filler hose at the tank itself (this is easier in the long run) One worm clamp.

Lower the tank enough to access the top of the tank and the worm clamp for the filler hose and the 1" vent hose.



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The old lift pump supply and return lines going in the top of the tank are plastic be careful not to bend or kink them If you are using the lines again.
The clips are a pain to release the line even worse than Ford.
I just capped mine not to be used again. (draw straw install eliminates this)

Unplug the wiring harness for the fuel tank sender and in tank pump.
Remove the EPA evap hose.



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Lower the tank and remove the sender assembly retaining collar with a strap wrench. Normally this is not necessary to do if you are installing a new draw straw with your fuel pump.
Just cap the fuel feed and return lines and their associated nipples.
Important note:
The only reason for pulling the sender assembly is I want to show an issue with Dodge's Fuel sender. (Picture 3rd down)
While the tank is out check the sender assembly for damage that causes what is know as the 1/4 tank syndrome. The sender has been known to stick hang up and give false readings usually leaving people stranded thinking they had fuel in the tank still.


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Locating a good spot to put the new draw straw is important.
You need a flat area on the tank large enough to cut a hole and still have room for the grommet.
Locate the spot that will be the lowest point when the tank is installed. In other words if your truck sits high in the back you may want to move the straw forward so the straw will always be in fuel.



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Cut your hole for the new draw straw, deburr it and install the grommet. Check your instructions for hole size.




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Once the hole is cut in the tank, take the draw straw and insert it in the tank cut the length of the straw to the dimension that gives you 1/4" to 3/8" inch off the bottom of the tank.
Measure carefully! remember the 90 degree fitting must sit in a grommet that raises the straw up slightly.
Notch the draw straw as shown if you want to I like this better than the flat cut.




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This completes the tank work attach the fuel feed hose to the new draw straw fitting.



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See part two for continuation Thanks!