AirDog A7SABD540 II-5G DF-165 Lift Pump for 1989-1993 Dodge 5.9L 12V Cummins

Vehicle Fitment

• 1989-1993 Dodge/RAM 5.9L 12V Cummins (VE-44 injection pump)

Fitment Notes

• This system is designed specifically for the first-generation 12V Cummins equipped with the Bosch VE-44 rotary injection pump - the engine configuration found in 1989-1993 Dodge Ram trucks. The pressure output connects directly into the side of the VE-44 injection pump, bypassing both the factory fuel filter housing and the factory frame-mounted mechanical fuel pump.
• This system is not compatible with 1994-1998 P-pump (Bosch P7100) 12V Cummins trucks - that application requires A7SABD524. It is also not compatible with Common Rail Cummins engines (1998.5+).
• The Fuel Module Upgrade Kit included with this system installs inside the factory fuel basket in the tank, creating a clean suction path via a factory-style 1/2" bulkhead fitting. The air/vapor separated during operation is returned to the tank through the factory 3/8" suction line once it has been modified per the installation instructions.
• The 1989-1993 Cummins is known for a fuel starvation issue below approximately 1/4 tank due to the tank's fuel outlet geometry. An optional fuel tank sump (PureFlow DRX09SMP) is available separately and is recommended for trucks that regularly run below a quarter tank or are used in off-camber applications.
• CARB E.O. Number D-595-3. This system is California Air Resources Board compliant for the listed applications.
• AirDog's lifetime warranty applies. Warranty registration must be completed within 30 days of purchase. The warranty is voided on any unit purchased below MAP price ($816.00) unless purchased during an approved AirDog sale.

Features

• The AirDog II-5G DF-165-5G is the premium tier of PureFlow's lift pump lineup, featuring the 5th-generation motor design with a 4-bearing motor and intermediate shaft. This reduces pump noise and vibration compared to earlier AirDog motor generations and improves long-term motor reliability under continuous high-demand operation.
• The dual feed design supplies fuel to both sides of the internal gerotor pump simultaneously, significantly reducing cavitation at the pump inlet - particularly important at high flow rates and when fuel quality or tank level creates marginal suction conditions.
• Demand flow technology recirculates fuel not consumed by the engine back through the diaphragm regulator to the suction side of the pump, rather than returning it all the way to the tank. This keeps the pump from over-fueling the system and reduces heat buildup in recirculated fuel.
• The integrated fully adjustable diaphragm pressure regulator is the key advancement of the II-5G over previous AirDog generations. It provides more consistent fuel pressure output across a wider range of flow rates and temperatures, and can be boost compensated using the AD-BOOSTCOMP kit (sold separately) to maintain fuel pressure proportional to boost on modified engines.
• At 165 GPH, this system flows enough fuel to support moderately modified 1989-1993 12V Cummins trucks, covering applications from stock through tuned builds with upgraded injectors. Trucks requiring maximum fuel flow for race or extreme high-horsepower applications should consider the DF-220 variant.
• The included 2-micron fuel filter (FF100-2) and water separator (WS100) are mounted on the pump head and filter the fuel to a finer level than the factory filtration system. The water separator removes 92% of water per SAE spec J1488.
• The 12-gauge wiring harness with Metri-Pack 280 connectors handles higher current flow than the previous Deutsch 2-pin connector design, reducing heat buildup at the electrical connections over long service life.
• Manufactured in Shelbyville, Indiana, by PureFlow Technologies.

Specifications

• Part Number: A7SABD540
• Brand: PureFlow AirDog
• Series: AirDog II-5G
• Model: DF-165-5G
• Flow Rate: 165 GPH (Gallons Per Hour)
• Fuel Pressure: Preset at 10-13 PSI
• Regulator: Fully adjustable integrated diaphragm type; boost compensatable
• Motor: 4-bearing with intermediate shaft (5th generation)
• Mounting: Frame rail; sandwich plate mounting system
• Fuel Draw: Fuel Module Upgrade Kit in factory fuel basket; 1/2" bulkhead fitting
• Pressure Connection: Side of VE-44 injection pump (bypasses factory filter housing and mechanical pump)
• Air/Vapor Return: Factory 3/8" suction line (modified)
• Fuel Filter Included: FF100-2 (2-micron)
• Water Separator Included: WS100
• Wiring: 12-gauge harness, Metri-Pack 280 connectors
• CARB Compliant: Yes - E.O. Number D-595-3
• Country of Origin: USA (Shelbyville, Indiana)
• Weight: 27 lbs
• Warranty: AirDog Lifetime Warranty (register within 30 days)

Included Components

• AirDog II-5G DF-165-5G pump head assembly
• Fuel Module Upgrade Kit (installs in factory fuel basket)
• Sandwich plate frame rail mounting brackets and hardware
• FF100-2 2-micron fuel filter
• WS100 water separator
• Fuel lines, fittings, and hardware
• 12-gauge wiring harness with Metri-Pack 280 connectors
• Full-color installation manual (#10 Rev. 11-13-24)

Product Description

The AirDog A7SABD540 is the II-5G DF-165-5G Air/Fuel Separation System for the 1989-1993 Dodge Ram 5.9L 12V Cummins equipped with the Bosch VE-44 rotary injection pump. It is PureFlow's top-tier lift pump and fuel conditioning system for this application, combining 165 GPH of clean, de-aerated fuel delivery with the 5th-generation motor, fully adjustable diaphragm regulator, and demand flow technology that distinguish the II-5G from earlier AirDog generations.

The VE-44 injection pump relies entirely on the factory frame-mounted mechanical lift pump for its fuel supply - a pump that is adequate for stock engines but becomes a bottleneck on modified trucks and degrades over time on high-mileage vehicles. The AirDog II-5G replaces this mechanical pump and adds upstream filtration by connecting directly to the side of the VE-44, bypassing both the factory pump and filter housing. Fuel is drawn from a Fuel Module Upgrade Kit installed in the factory fuel basket, passed through the integrated water separator and 2-micron filter, and delivered to the injection pump at a stable, regulated 10-13 PSI. Entrained air and vapor separated during this process are returned to the tank through the modified factory 3/8" suction line.

Key II-5G advantages over the previous 4G generation include the 4-bearing motor with intermediate shaft for quieter, more reliable long-term operation; the dual feed gerotor design that reduces cavitation at high flow rates; and the integrated adjustable diaphragm regulator, which provides more precise and stable pressure control and supports boost compensation via the AD-BOOSTCOMP kit (sold separately). For trucks that routinely run below a quarter tank, the optional DRX09SMP fuel tank sump (sold separately) addresses the known suction limitation of the 1989-1993 tank design. Manufactured in the USA and covered by AirDog's lifetime warranty when registered within 30 days of purchase.