Diesel engines are built to last, but just because they keep operating does not mean they are operating efficiently. Components can wear out, expensive fixes can be necessary, and an engine can keep pushing along for years while using more fuel than it needs to. If you want to know how to prolong the life of a diesel engine—and equally important, maintain its performance—you need to understand the fundamentals of how they work and prioritize maintenance. It’s also a good idea to invest in high-quality components, like AirDog® Heavy Duty Diesel Fuel Systems. AirDog® works to keep diesel engines in good condition by removing moisture, particulates, and entrained air and vapor. By ensuring only pure, clean diesel enters your fuel injectors and therefore your engine, you can make significant strides towards prolonging the life of your engine. The Basics of Diesel Fuel Systems The life expectancy of a heavy-duty diesel engine can be greater than 1,000,000 miles. Part of what makes these engines last so long is their simplicity. The fuel system only has five major components: fuel tank, fuel transfer pump, filters, injection pump, and fuel injectors. The fuel transfer pump pulls fuel from the tank and through the filters, which remove particulates and separates water from fuel. The injection pump pushes the cleaned fuel through the injectors and into the engine for combustion. Stock systems do a serviceable job of getting fuel to the engine without too many contaminants. However, there are drawbacks to these standard systems. The gear-driven pumps can introduce air into the fuel, adding the air that already occurs through fuel slosh. Over time, this can lead to wear and tear on the fuel injectors, reduce fuel economy, and even prevent the engine from starting. The Role of AirDog® Systems AirDog® was designed by our engineers to solve the common problems that come with basic diesel fuel systems. Our systems accomplish this goal in several ways, including: Removing Entrained Air A diesel fuel system that is operating perfectly never lets air reach the fuel injectors. One of the main purposes of AirDog® fuel systems is to remove entrained air from diesel fuel before pushing that fuel to the fuel injectors. Along with removing solids from the fuel, it also sends the fuel through the AirDog® Fuel Preporator, the world’s first patented system for removing air from fuel. When the air is removed, it is sent back to the fuel tank. Optimizing Fuel Pressure Removing existing air is not enough to protect your engine. It’s also necessary to minimize air and vapor in the fuel lines and to ensure that the air-free fuel makes it from the Preporator without the reintroduction of air. Our systems accomplish these goals in a few different ways. Fuel pressure is maintained by integrated fuel pumps included in the AirDog® system along with the filtration components. These pumps maintain appropriate pressure to minimize vapor creation in the fuel lines and reduce strain on the existing transfer pump, which extends its life. [...]

One of the things that makes AirDog® fuel filtration systems so effective is that they are customized for specific applications. It’s important to select the right filters for your specific diesel engine, whether you are operating a commercial heavy truck or a pickup truck. We make it easy to identify the correct fuel filters for your vehicle so there is no question about which is right for your needs. We encourage users of AirDog® fuel filters to always keep a spare set of fuel filters when out on the road. Otherwise, a clogged filter could result in unwanted downtime and calling in expensive mechanical help—when all you really need is another set of filters to screw on. Understanding AirDog® Filter Options We try to make it as easy as possible to know which fuel filter is right for a diesel engine. Our semi-truck filters are categorized in the 200s and our pickup truck filters are categorized in the 100s. A filter in the 200s is only appropriate for heavy-duty commercial vehicles, while a filter in the 100s is only appropriate for pickup trucks. You can easily tell if the product is a fuel filter or a water separator by the letters at the beginning of the filter name: FF for fuel filter, WS for water separator. Let’s take a closer look at our filter categories so you know how to know which filter to buy for your vehicle.   Commercial Medium- and Heavy-Duty Trucks (Class 4-8) FF200-MG-6: This AirDog® fuel filter is performance-matched to the AirDog® FPII and Champ systems. Using microglass media, it filters down to 6 microns while allowing a freer flow of fuel than traditional cellulose filters. This filter can typically be operated for up to 40,000 miles as long as no algae or other serious contaminants are present. WS200-HS: This water separator/pre-filter is performance-matched to get the most out of the AirDog®FPII system. It should be changed when changing the fuel filter. It features high-performance Hydrosorb media, which allows it to remove water and large particulates with excellent efficiency. It’s always a good idea to carry an extra set of fuel filters and water separators when operating heavy trucks. We offer multi-packs at cost savings to ensure you always have a spare set in case of clogs while on the road. Industrial Applications, Marine, and Light Duty Trucks FF100-2: Manufactured with high-quality Stratopore media, this 2-micron fuel filter is well-suited to get the most out of the smaller AirDog® Heavy Duty and Industrial Diesel Fuel Systems for industrial, marine, and light duty truck applications. WS100: This water separator/pre-filter is performance-matched to get the most out of the AirDog® FPII Diesel Fuel Systems. The filter is serviceable and simply requires draining at regular intervals. Remember, our 200-level filters are for heavy-duty truck and other high-demand applications, and our 100-level filters are for light-duty pickup trucks and other applications using the 3” diameter filters . The Importance of Spare Filters Any experienced commercial driver can tell you how expensive [...]

One question we get asked a lot concerns the impact of AirDog on fuel efficiency. The way that AirDog improves the fuel delivery process to the engine, including providing cleaner, air-free fuel, and maintaining optimal pressure to the fuel injectors, is going to result in improved diesel fuel efficiency in a heavy-duty engine. But the question is, how much? That’s a surprisingly complicated question. We generally can say that operators can expect fuel economy to improve by three-tenths of a mile. However, we have had reports of greater improvements, but there are so many factors that go into fuel economy that we can’t make specific guarantees. When you use AirDog systems, you should see an improvement in fuel economy. But how much depends on a variety of factors that we will explore below. The Complexity of Fuel Efficiency When it comes to examining fuel efficiency, there are numerous things to consider, including: How does the operator drive the vehicle? What is the vehicle type? What kind of engine is being used? What is the terrain like? What is being hauled? What quality of fuel is being used? As you can see, there are plenty of variables to consider, and these are only some of them. It certainly makes sense that AirDog users and potential customers would want to know how much AirDog will improve their fuel efficiency. Unfortunately, the generalized answer we have to give is, “It depends.” Major Factors Influencing Fuel Efficiency Several major factors should always go into the fuel efficiency equation. These include: Driver Behavior You have likely noticed that different drivers can take significantly different approaches to operating a vehicle. One driver might take a very cautious approach, accelerating slowly and steadily from each stop, never going above the speed limit, and generally taking it as easy as possible on the vehicle. Another driver might let nothing get in the way of reaching their destination. They might stomp the gas pedal to the floor after each stop, have a rule to travel at least 10 mph above the speed limit (if not more), and demand as much out of the vehicle as possible. These are examples of extremes, and most drivers fall somewhere in the middle. However, studies have shown that driver behavior can affect fuel economy by as much as 30% at highway speeds and 40% in stop-and-go traffic. Vehicle and Engine Type The vehicle and engine type can make a significant difference in fuel economy. There are so many different diesel vehicles out there, even if you only consider heavy-duty trucks. Over a hundred years of diesel trucks have been manufactured. While it’s unlikely someone will be driving a hundred-year-old truck, the point is that many different trucks can use AirDog. And that’s only the trucks. When you add in the engines, you have many potential combinations. A modern diesel engine is a beautiful, highly efficient machine. Older diesel engines are workhorses, but efficiency was not as much of a concern. The increased fuel [...]

The diesel engines found in heavy-duty trucks can seem bulletproof. It’s true, they are tough and durable. But they are not invincible. Some things—like air in the fuel system—can cause serious problems that you want to avoid as much as possible. Air in the fuel line symptoms can include difficulty starting, reduced power, and even failing to start at all. And the unfortunate reality is that you can’t completely keep air out of the system. The sloshing diesel in your fuel tank is going to get air bubbles in it. However, you can remove the air before it gets to the engine with AirDog®. Understanding How Air Enters Diesel Fuel Systems It’s important to understand where air in the fuel line of a diesel engine can enter the system. That way, you can do what you can to minimize the risk and address the problem when it does occur. Fuel Sloshing The fuel in the fuel tank of a moving vehicle is always sloshing around. Every bump, corner, stop, and acceleration shifts the fuel around. All that sloshing introduces air into the fuel. Tank slosh stirs up fuel into a bubble-filled froth and that vapor is pulled into the fuel line along with the fuel. There is no economical way to avoid air in the fuel tank. The best option is to have a system for removing that air before it gets to the engine. System Leaks and Broken Fittings The hoses and fittings that make up the fuel system can be the source of air penetration. Hoses degrade and can develop holes. They can be punctured by accident. Fittings break or can be installed incorrectly. Any part of the fuel system that wears out, breaks, or is improperly installed, can be a source of air into the system. Keeping a regular maintenance schedule for your diesel can help prevent this type of issue and identify leaks when they do occur. Cavitation and Vapor Formation With many engines using a gear-driven transfer pump, it’s common to see cavitation which can lead to vapor formation. The system is under a kind of suction from the transfer pump which contributes to vapor development. As you follow your fuel lines, you will notice how often they take sharp turns to make their way through the maze under the hood. Those sharp turns and nooks in the fuel system contribute to vapor formation as well. The Impact of Air on Diesel Fuel Systems Air in a diesel fuel system can lead to frustrating problems. If enough air is present it can lead to airlock, which prevents fuel from reaching the engine. When severe, the engine won’t even start. Even when the engine does start, you can still experience performance issues like unstable idling, black smoke from the exhaust, decreased power, and uneven engine operation when traveling at high speeds. Air can cause excessive wear on parts as well, like the fuel injectors. When the fuel injectors are operating without enough fuel there is not [...]

Diesel engines can run in extreme conditions, but one thing they do not like is air in their fuel systems. Air in the fuel system can delay or prevent the diesel fuel from reaching the injectors, making your engine difficult to start, reducing the engine’s power, or, in severe cases, causing the inability to start the engine. Air can enter your diesel engine’s fuel system in several ways, most commonly by running out of fuel, from leaks in your fuel lines, or following a fuel filter change.  Before attempting to bleed the air from the fuel system, ensure you have determined how air entered the fuel system so air does not reenter the system after completing the bleeding process.  Also, since you already need to work through the bleeding process, consider replacing the fuel filter if it is old or approaching the end of its life. Of course, you should also exercise caution and follow all safety guidelines throughout this process.  Assuming you are satisfied that you do not have an unremedied problem that will continue allowing air into the system, the 7-step process detailed below should resolve your issue. So, let’s get started. Step 1: Gather Necessary Tools and Materials The first step is to gather the tools and other materials needed for the job. These include: Wrench or socket set Bleeder screw key or wrench Clean rags or towels Safety goggles Diesel fuel Step 2: Locate the Fuel System Components Step 2 is to familiarize yourself with the engine you are working on and identify the key components of its diesel fuel system, including the fuel tank, fuel lines, fuel filter, and fuel injectors. Take a moment to review the engine’s fuel system layout and connections. Step 3: Prepare the Fuel System for Bleeding Step 3 involves working with the fuel filter, so confirm that you turned off the engine and removed the ignition key from the cylinder. Next, locate the fuel filter and determine whether it has a built-in bleeder screw. If the fuel filter has a bleeder screw, move to Step 5. If the fuel filter lacks a bleeder screw, then go to Step 5. Step 4: Bleed the Fuel System at the Fuel Filter Assuming your fuel filter has a bleeder screw, follow these steps: Position a clean rag or towel beneath the bleeder screw to catch any fuel spills. Use a wrench or bleeder screw key to loosen the screw in a counterclockwise direction. Loosen the screw slowly. A mixture of air and fuel should bleed from the loose screw. Allow the bleeding to continue until only fuel (without air bubbles) flows from the screw. Tighten the bleeder screw securely. If the fuel filter does not have a bleeder screw, you may need to loosen the filter slightly to allow the air to escape. Step 5: Bleed the Fuel System at the Fuel Injectors If your fuel filter does not have a bleeder screw, or if you think air remains in the system, you [...]

When it comes to enhancing the performance of your diesel engine, few components offer as many benefits as AirDog® Fuel Systems. Not only do they improve fuel efficiency and acceleration, but they also reduce engine wear and tear and exhaust emissions. Still, the question remains: Can AirDog® Fuel Systems do all that and add horsepower? Thankfully, for heavy-duty truck owners, the answer is an unqualified "Yes." Follow along below, and let us explain how that happens. The Problem with Entrained Air in Diesel Fuel As a truck rolls down the road, hitting bumps and making turns, the diesel fuel in the tank sloshes around, mixing air bubbles into the fuel. Contrary to popular belief, those air bubbles do not float up and out of the fuel quickly enough to prevent them from entering the fuel line and onto the engine. Besides air, moisture also enters the fuel due to improperly sealed storage tanks or through condensation in the fuel tank as the outside air warms and cools. Both situations present problems because diesel engines do not burn fuel with entrained air as efficiently as pure diesel fuel, and the problem becomes worse when the fuel contains moisture. Thinking about how the diesel fuel's air and moisture cause problems, consider how the typical fuel filter functions. By design, most fuel filters perform one job: they trap solid contaminants in the fuel before they enter the engine. While trapping solids is critical, it is insufficient because standard fuel filters do not remove air and moisture, and performing those steps makes AirDog® systems different. How AirDog® Fuel Systems Work The AirDog® Fuel System's first step is to send the fuel through a water separator that eliminates moisture and particulates down to 30 microns. Second, the fuel passes through the AirDog® fuel pump, and onto the fuel filter, which removes particulates down to 6 microns, and air from the fuel, sending the separated air and a small amount of fuel back to the fuel tank. The AirDog® integrated fuel pump sends the pure diesel fuel to the engine at a regulated positive pressure. The integrated pump also reduces the opportunity for air to enter the system by keeping vapors out and reducing vapor-causing cavitation. AirDog® Fuel Systems significantly enhances throttle response and power delivery by supplying the engine with air-free fuel, better and consistent fuel pressure due to the integrated pump, and improved fuel spray patterns due to the lack of air in the fuel. By sending pure fuel at the correct pressure, the fuel gets sprayed properly, and the engine burns the optimal fuel-air mixture for the current engine setup, resulting in increased horsepower. This improvement is particularly noticeable when driving at higher elevations, where traditional fuel systems often struggle. Additional Benefits of AirDog® Fuel Systems Besides boosting engine horsepower, AirDog® Fuel Systems offers many other benefits, so let's focus on five of the most important. Enhanced Fuel Mileage: A notable advantage of AirDog®Fuel Systems is improved fuel efficiency. The system ensures [...]

If you own or operate a heavy truck, you know your engine must run smoothly and efficiently. However, an issue that disrupts the smooth operation of many engines is the presence of air in the fuel line, which causes several problems, including a condition known as an airlock.  To help you avoid this problem, we will review the signs you have air in your diesel fuel lines and the problems caused, including airlock, and suggest several ways to address those issues. Signs of Airlock and Its Causes Airlocks occur when air enters your fuel system and keeps the diesel fuel from reaching the injectors. Unable to pass fuel through the bubble stuck in your system, typical symptoms include difficulty starting the engine, reduced engine power after starting, and, in severe cases, the inability to start the engine. Airlock can occur due to your engine running out of fuel, leaks in your fuel lines, air bubbles in your fuel, or following a fuel filter change when the fuel filter does not get primed correctly. Running out of fuel will almost certainly result in an airlock, but that issue is resolved by not running out of fuel. Leaks in your fuel lines may cause sporadic airlocks and reduced engine power, a problem that requires you to repair the problem parts. Airlocks due to air in the fuel and improper filter-changing procedures can be addressed by bleeding and properly priming the fuel lines, which can be time-consuming. However, as shown below, these airlocks are either prevented or more easily resolved in engines with AirDog® fuel systems.  Understanding Air in Diesel Fuel As your truck runs down the road, the diesel fuel in the tank sloshes around, mixing tiny air bubbles into the fuel. Contrary to popular belief, those air bubbles do not simply float up and out of the fuel. Instead, many air bubbles remain in your fuel and enter the fuel line, eventually reaching the engine.  Besides air in your diesel fuel, moisture also enters your fuel due to improperly sealed storage tanks and condensation in the fuel tank stemming from changes in outside air temperature. Both situations lead to less efficient fuel combustion and potential engine damage. The Problem with Standard Fuel Filters Although standard fuel filters can effectively trap solid contaminants, they do not remove air and moisture from diesel fuel, so they are ineffective at removing the air bubbles that can cause airlock. The standard fuel filter and fuel system are also susceptible to allowing large amounts of air to enter during a fuel filter change. This situation occurs because the fuel filter replacing the old filter needs to be filled with fuel and later topped off to limit the air introduced into the fuel lines.  Following a fuel filter change, those with airlock symptoms must bleed the lines and manually prime the fuel system or use the ignition to prime the fuel system (on some engines). Each process requires time and labor; time, like labor, is money. The [...]

It makes sense to optimize the performance of your truck or fleet, and there are many opportunities to do so. However, fuel is responsible for up to 40% of fleet operating costs, while maintenance and repair costs often account for another 10%, resulting in fleets and independent truckers alike looking for ways to contain those costs. One of their often-overlooked opportunities is the truck's fuel filtration system, which is crucial for engine power, efficiency, and longevity.  AirDog® fuel systems stand at the top of the class for their ability to remove water and entrained air from diesel fuel, and along with other systems benefits, they provide cost savings. Of course, an obvious question is whether AirDog® fuel systems are worth the money. Does investing in an AirDog® fuel system make financial sense, and how long does it take to recover my investment? Of course, your payback time will vary by your model, application, and mileage per year. Still, we show below that investing in an AirDog® fuel system for an over-the-road truck can pay for itself in 3 or 4 months based only on fuel savings, and the investment in the AirDog® fuel system continues reaping financial and performance benefits throughout the truck's life. AirDog® Fuel Systems Save Money It isn't often that you find an investment to improve your truck's fuel efficiency and performance that also pays for itself within 3 or 4 months, but that is the case with AirDog® fuel systems. As we will show, it is one of the most intelligent choices for improving your truck's performance while saving money. Consider the numbers for an over-the-road truck without an AirDog® fuel system that travels 120,000 miles yearly and averages 6 miles per gallon. Both the annual mileage and fuel efficiency fall within the normal range. So, what are the economics of a truck when we install an AirDog® fuel system? Our experience shows that trucks with AirDog® fuel systems typically achieve 5 percent better fuel economy than a standard fuel system. In our example, our 6 miles per gallon truck becomes a 6.3 miles per gallon with an AirDog® fuel system, and at 120,000 miles per year, its fuel usage drops by 952 gallons per year, leading to considerable cost savings. How much money savings you receive will depend on fuel prices, but when diesel costs $4.00, $4.25, or $4.50 per gallon, you can count on annual cost savings of $3,808, $4,046, and $4,284, respectively. Now, comparing those cost savings to the price of an AirDog® FPII 4G Fuel Air Separation System shows you break even in only 3 or 4 months. From that point on, every mile driven produces additional savings, allowing you to keep that 5 percent in your pocket rather than increasing your fuel expense. The math is simple. AirDog® fuel systems save enough money at the pump to pay for themselves quickly, but fuel savings are not their only contribution to your bottom line. They also keep your truck out of the [...]

The performance of a heavy-duty truck depends on the quality of the diesel fuel delivered to its engine, and a critical component in ensuring fuel quality is the fuel filter. Optimal filtering performance comes from a high-quality fuel filter that matches the engine specifications and gets replaced as needed. Fuel filters have a limited lifespan, so it is essential to know when to replace your diesel fuel filter to obtain optimal performance from your engine and truck. Recent years have brought changes in diesel fuel, diesel engines, and system components like fuel filters, so this blog post provides a guide to regular maintenance and the signs suggesting the need to change your fuel filter. The Importance of a Diesel Fuel Filter The fuel filter plays a crucial role in heavy-duty diesel engine performance by removing contaminants and ensuring high-quality diesel fuel reaches the engine. With today's high-pressure fuel injection, it is more important than ever that the fuel filter minimizes the air, water, and other contaminants. Without effective filtering, these impurities damage the engine over time and degrade performance and efficiency. In addition, since replacing fuel filters is far less expensive than replacing damaged fuel injectors, it is common sense and intelligent business practice to monitor and replace your fuel filters as needed.   Identifying the Need for a Diesel Fuel Filter Replacement There are two primary methods to identify the need to replace your fuel filter. One approach is consistently checking the fuel filter as part of your regular maintenance practices. While consistent checking is necessary, it cannot prevent fuel filter problems resulting from contaminated fuel or other challenges. Since some fuel system challenges are difficult to anticipate, knowing the warning signs that you may need to replace your fuel filter is essential. So, here are a few warning signs of the need to replace your diesel fuel filter and reduce the potential for future engine problems.  Decreased Fuel Efficiency or Performance A drop in fuel efficiency or performance is among the first indicators of a worn-out fuel filter. A clogged filter restricts fuel flow to the engine and affects the fuel system's ability to deliver the proper fuel volume to the engine consistently. Insufficient fuel flow can cause the engine performance to suffer because the engine does not always inject fuel at optimal levels. As the engine strains for fuel, it may also receive more than optimal, reducing fuel efficiency. A drop in performance when accelerating or on a grade and a decrease in fuel efficiency that shows up at the pump suggests the need to check your fuel filter.  Strange Engine Noises The inadequate fuel supply from a clogged fuel filter can cause the engine to sound like it is choking. At the same time, the increased strain on the fuel pump can create a buzzing sound as the pump tries to pull fuel through the obstructed filter. Difficulty Starting the Engine or Rough Idling Diesel engines require the most fuel when starting, and a clogged fuel filter [...]