Replacing Air Dog Fuel Filter: Step-By-Step Guide

Changing the fuel filter on an AirDog® filtration system is a straightforward process, but it requires careful preparation and attention to safety protocols. This innovative water separator and filtration system for heavy-duty diesel fuel systems requires periodic filter changes to maintain optimal performance and efficiency. The process involves basic steps such as gathering the necessary tools and supplies, following safety precautions, identifying the correct replacement filters, and properly disposing of the used filters. The actual replacement process includes draining and removing the old filters, preparing and installing the new filters, priming the system, and performing final checks to ensure a secure and leak-free installation.

Changing an AirDog® Fuel Filter

Prepare tools and supplies

Before you begin the process of changing your AirDog® fuel filters, it is important to ensure that you have all the necessary tools and supplies on hand. Here is a detailed list of what you will need:

• Replacement AirDog® water separator and fuel filter set: It is crucial to have the correct replacement filters specifically designed for your heavy-duty diesel system. AirDog® offers a range of replacement filters, including the WS100 Water Separator and FF100-2 Fuel Filter for light-duty systems, and the WS200-HS Water Separator and FF200-MG-6 Fuel Filter for heavy-duty systems.
• Clean container: You will need a clean container to catch any fuel or residue that may drip during the removal and installation process. It is also important to have a container for properly disposing of the used filters.
• Nitrile gloves: These gloves will protect your hands from diesel and other contaminants during the filter change.
• Rags or paper towels: Have plenty of rags or paper towels readily available for cleaning up any spills or residue during the process.
• Socket or wrench set: You may need a socket or wrench to unscrew and remove the old water separator and fuel filter.
• Handwashing supplies: Even with gloves, there is a possibility of getting diesel on your hands, so have soap, water, and a way to wash your hands nearby.

Additionally, it is recommended to have a spare set of filters in your vehicle at all times, as the need for a filter change can arise unexpectedly.

Now that you have gathered all the necessary tools and supplies, you can proceed to the next step of changing your AirDog® fuel filters. Remember to follow safety protocols and work in a well-ventilated area to ensure a smooth and safe filter change process.

Follow safety protocols

When changing your AirDog® fuel filters, safety should be your top priority. Here are some detailed safety protocols to follow:

Park in a Well-Ventilated Area

It is crucial to change your filters in a well-ventilated area due to the use of diesel fuel. The new water separator in the AirDog® filtration system requires you to fill it with diesel before installation, and this step should only be performed in a space with adequate ventilation to ensure your safety.

Engage the Parking Brake and Turn Off the Engine

Before beginning any maintenance work on your heavy-duty vehicle, it is essential to engage the parking brake and turn off the engine. This basic safety measure will prevent any accidental movements of the vehicle during the filter replacement process.

Keep Rags and a Clean Container Handy

Always have rags or paper towels readily available to clean up any fuel spills that may occur during the filter change. Additionally, use a clean container to catch any fuel or residue that drips during the removal and installation of the filters. This will help you maintain a clean and safe workspace.

Properly Dispose of Used Filters

Before removing the old filters, be prepared for their proper disposal. This includes having a suitable container to place the used filters in and knowing the local regulations for disposing of such waste. Improper disposal can result in significant fines, so it is important to be informed about the correct disposal methods in your area.

Wear Protective Gear

When working with diesel fuel and changing filters, it is important to protect your hands with nitrile gloves. Additionally, keep in mind that you may still get diesel on your skin, so have a way to wash your hands thoroughly after completing the task.

By following these safety protocols, you can help ensure that you change your AirDog® fuel filters correctly and maintain the health and efficiency of your diesel engine.

Identify AirDog® filters

AirDog® fuel filtration systems are customized for specific applications, so it's important to select the right filters for your diesel engine. AirDog® provides high-quality water separators and fuel filters designed for heavy-duty diesel systems. There are multiple filter types designed for different systems, so make sure you have the correct replacement filters for your specific system before removing the old filters.

AirDog® offers a range of replacement filters and water separators to maintain your AirDog® and Champ™ diesel fuel systems. The company recommends using original AirDog® branded filters and accessories to ensure optimal performance and longevity.

You can easily identify the correct fuel filters for your vehicle by the filter name. For example, filters in the 200s, such as the FF200-MG-6, are 3.75” diameter cans for heavy-duty commercial trucks, while filters in the 100s, such as the FF100-2, are 3.0” diameter cans for light-duty pickup trucks and industrial applications. The letters at the beginning of the filter name indicate the type of filter: FF for fuel filter and WS for water separator.

The AirDog® FF100-2, for example, is a 2-micron fuel filter designed for pickup trucks and light industrial systems. The FF200-MG-6, on the other hand, is a 6-micron fuel filter suitable for heavy-duty trucks and industrial systems.

It is also important to note that AirDog® fuel filters are performance-matched to specific AirDog® systems. For instance, the FF200-MG-6 fuel filter is designed for the AirDog® FPII and Champ systems, while the WS200-HS water separator is performance-matched to the AirDog® FPII system.

Prepare for the change

Before you begin the process of changing your AirDog® fuel filters, it is important to ensure that you have everything you need and that you are well-prepared. This step is crucial to ensure that the filter change goes smoothly and efficiently. Here are some detailed instructions to help you prepare:

Firstly, locate the existing AirDog® water separator and fuel filter. Identify their positions and make sure you know how to access them easily. This will make the removal process simpler and help you anticipate any potential challenges.

Secondly, gather all the necessary tools and supplies. It is recommended to have a replacement AirDog® water separator and fuel filter set ready. Make sure you have the correct replacement filters specifically designed for your heavy-duty diesel system. Keep these replacement filters within easy reach during the process.

Additionally, you will need a clean container to catch any fuel or residue that may drip during the removal and installation. Place this container beneath the filters before you start. It is also a good idea to have rags or paper towels to clean up any spills or residue.

Wearing nitrile gloves is recommended to protect your hands from dirt and fuel. If you anticipate the possibility of coming into contact with diesel, it is important to have a way to wash your hands thoroughly afterward.

For the removal process, you may need a socket or wrench set. These tools can help you unscrew the old water separator and fuel filter if they are tightly secured.

Finally, before you begin, ensure that you are parked in a well-ventilated area. Safety should be your top priority when performing any maintenance on a heavy-duty vehicle. Engage the parking brake, turn off the engine, and be prepared to properly dispose of the used filters. Know the local regulations for disposal and have a container ready to place the used filters in.

Remove old filters

Before removing the old filters, place a clean container beneath them to catch any fuel or residue that may drip during the process. First, you will need to remove the water separator. Unscrew the old water separator from its housing using a wrench or socket. Allow any remaining fuel to drain into the container. Dispose of the old water separator properly.

Next, you will remove the old fuel filter. Carefully unscrew it counterclockwise, being careful not to spill any fuel. If fuel starts spilling, keep the filter over the container until it stops. Dispose of the old fuel filter properly. It is important to note that you should not fill the old filter with diesel, as this could introduce particles into your fuel system.

Once you have removed and disposed of the old filters, you can prepare the new filters for installation.

Remember to follow basic safety protocols when changing your AirDog® fuel filters. This includes parking in a well-ventilated area, engaging the parking brake, turning off the engine, and keeping rags ready to clean up any fuel spills.

Frequently asked questions