Airdog Raptor RP-4G-100 Fuel System Instruction Manual

1. Product Overview

The Airdog Raptor RP-4G-100 is a high-performance fuel system designed for 2001-2010 6.6L Chevy Duramax diesel engines. This system functions as a lift pump, ensuring consistent fuel delivery to the injection pump. It is engineered to provide 100 Gallons Per Hour (GPH) of fuel flow, suitable for stock fuel trucks.

Key features of this system include:

• Frame Rail Mounting: Utilizes a sandwich plate mounting system for secure installation.
• Internally Regulated: The pump is internally regulated, eliminating the need for an external return line.
• Optimized Fuel Flow: Delivers 100 GPH to support engine performance.

2. Package Contents

Carefully unpack the box and verify that all components listed below are present. If any items are missing or damaged, please contact Airdog customer support immediately.

Image 2.1: All components of the Airdog Raptor RP-4G-100 Fuel System. This includes the main pump assembly, fuel lines, mounting hardware, electrical harness, and various fittings.

The package typically includes:

• Raptor RP-4G-100 Fuel Pump Assembly
• Two (2) Fuel Lines (long)
• Two (2) Frame Rail Mounting Plates
• Wiring Harness with Connectors
• Assorted Mounting Hardware (bolts, washers, nuts)
• Various Fuel Fittings (barb type)
• Two (2) O-rings
• One (1) Rubber Isolator/Mount
• Zip Ties

3. Setup and Installation

Safety Warning: Before beginning installation, ensure the vehicle's battery is disconnected. Work in a well-ventilated area and take appropriate precautions when handling fuel. Refer to your vehicle's service manual for specific procedures related to fuel system components.

3.1 Mounting the Fuel System

1. Identify a suitable location on the vehicle's frame rail for mounting the fuel pump assembly.
2. Utilize the provided sandwich plate mounting system to securely attach the pump to the frame rail. Ensure the mounting is rigid and free from obstructions.
3. Use the rubber isolator between the pump and the mounting plate to reduce vibration.

3.2 Fuel Line Connections

1. Suction Line: Connect the suction line from the Raptor fuel system to the factory suction fitting located on top of the vehicle's fuel module. Ensure all connections are tight and leak-free.
2. Pressure Line: Connect the pressure line from the Raptor fuel system to the factory injection pump feed line. This connection is typically found on the frame, near the fuel cooler, towards the rear of the vehicle.
3. Since the Raptor RP-4G-100 is internally regulated, a separate return line is not required.
4. Route fuel lines carefully, avoiding sharp bends, hot engine components, and moving parts. Secure lines with the provided zip ties.

3.3 Electrical Connections

1. Connect the wiring harness to the fuel pump assembly.
2. Follow the included wiring diagram for proper connection to the vehicle's electrical system. Typically, this involves connecting to a switched 12V power source and a ground.
3. Ensure all electrical connections are secure and protected from environmental elements.

4. Operation

Once properly installed, the Airdog Raptor RP-4G-100 fuel system operates automatically with the vehicle's ignition. When the ignition is turned on, the pump will activate to supply fuel to the engine's injection system. The 100 GPH flow rate ensures adequate fuel supply for stock applications, maintaining optimal fuel pressure and volume.

5. Maintenance

Regular maintenance is crucial for the longevity and optimal performance of your Airdog Raptor fuel system.

• Visual Inspection: Periodically inspect all fuel lines, connections, and electrical wiring for signs of wear, leaks, or damage. Address any issues promptly.
• Filter Replacement: While not explicitly detailed for this specific model in the provided information, fuel systems typically require periodic filter replacement. Consult the manufacturer's recommendations for filter service intervals to ensure clean fuel delivery and protect the pump and engine components.
• Mounting Security: Check the tightness of all mounting hardware to ensure the pump remains securely attached to the frame rail.

6. Troubleshooting

If you experience issues with your Airdog Raptor RP-4G-100 fuel system, consider the following troubleshooting steps:

• No Pump Operation: Check electrical connections, fuses, and relays. Ensure the pump is receiving proper voltage when the ignition is on.
• Low Fuel Pressure: Verify that the fuel tank has an adequate fuel level. Inspect fuel lines for kinks or obstructions. Check fuel filters for clogging (if applicable).
• Leaks: Inspect all fuel line connections for tightness. Replace any damaged O-rings or fittings.
• Diagnostic Trouble Codes (DTCs): If your vehicle displays a P0087 (low fuel rail pressure) or similar code, while the Raptor system can help maintain pressure, it may also indicate other issues such as worn injectors, especially under heavy load or high temperatures. Consult a qualified mechanic for further diagnosis if the issue persists after verifying the lift pump's proper function.

7. Specifications

8. Warranty and Support

For detailed warranty information, product registration, or technical assistance, please refer to the official Airdog website or contact their customer support directly. Keep your purchase receipt as proof of purchase for any warranty claims.

Airdog Customer Support: Refer to your product packaging or the official Airdog website for current contact information.