M-9424-M50B 2012 Boss 302 Intake Manifold INSTALLATION INSTRUCTIONS
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1 !!! PLEASE READ ALL OF THE FOLLOWING INSTRUCTIONS CAREFULLY PRIOR TO INSTALLATION. WARNING: CUSTOM CALIBRATION REQUIRED! CALIBRATION NOT INCLUDED! KIT CONTENTS: 1) Intake Manifold Assembly 2) Assembly Instructions (this document) THIS KIT REQUIRES: Boss 302 INTAKE MANIFOLD INSTALL KIT M-9444-M50B Fuel Vapor Hose Fuel Vapor Fuse Bracket and fasteners Fuel Line Air Inlet Tube assembly throttle body to air box
2 FUEL SYSTEM PRESSURE RELEASE: WARNING: WARNING: WARNING: NOTE: STEP 1: STEP 2: STEP 3: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. The fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. The Fuel Pump Driver Module (FPDM) is located in the spare tire stowage compartment. Disconnect the FPDM electrical connector(s). Start the engine and allow it to idle until it stalls. After the engine stalls, crank the engine for approximately 10 seconds to make sure the fuel injection supply manifold pressure has been released. Turn the ignition switch to the OFF position
3 : STEP 1: Disconnect battery at negative (black) terminal. Negative Terminal Negative Terminal Removed
4 STEP 2: STEP 3: Remove strut tower brace. (Note: Original strut tower brace will not fit with the Boss 302 intake) Remove intake cover from intake. Strut Tower Bolts Strut Tower Brace Strut Tower Bolts Intake Cover
5 STEP 4: Remove air cleaner box lid and tube assembly.
6 STEP 5: WARNING: Fuel Pressure must be released before performing the following step! Disconnect the fuel line by first removing the safety clip. Put on safety glasses. Fuel will spill out when you disconnect the line so it is best to place a rag below the connection to absorb the fuel that spills. Fuel line disconnect
7 STEP 6: Remove PCV tube from intake. PCV Tube
8 STEP 7: Remove vapor line and disconnect electrical connector from purge valve and throttle Body connector. Purge Valve Connector Vapor Line Throttle Body Connector
9 STEP 8: STEP 9: Disconnect vacuum line from intake to brake booster. Remove nuts holding down heater hose and vacuum line rails. Then remove vacuum line. Vacuum Line Brake Booster Connection Intake Connection STEP 10: Move heater hose off to the side and remove LH and RH fuel rail insulators. Fuel Rail Insulators
10 STEP 11: Unplug 8 injectors by pushing in clip and pulling straight out.
11 STEP 12: STEP 13: Confirm base of intake is clean of debris. Remove wire harness clips from rear of intake (4) places. Wire harness clip Wire harness clips
12 STEP 14: Remove (4) fuel rail bolts and loosen (6) intake bolts, Remove intake and place on work bench. Fuel rail bolt Intake bolt STEP 15: Cover intake ports on cylinder head with duct tape for now to keep any debris out.
13 STEP 16: STEP 17: STEP 18: Remove new intake from shipping box and place on bench next to your removed intake. Swap over fuel injectors, fuel rail and throttle body. Tighten Throttle body to spec. While holding the TB in the most upward position tighten the 4 bolts in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees. STEP 19: STEP 20: NOTE: NOTE: Remove tape from cylinder heads. Install Boss 302 intake onto engine. Clean the sealing surfaces with metal surface prep. Inspect the mating surfaces. Fuel rail removed from graphic for clarity. Using new gaskets, install the intake manifold. Tighten the 6 intake manifold bolts in the sequence shown in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
14 STEP 21: Install the 4 fuel rail bolts. Tighten in the sequence shown in 3 stages. Stage 1: Hand tighten. Stage 2: Tighten to 10 Nm (89 lb-in). Stage 3: Tighten an additional 90 degrees. STEP 22: STEP 23: STEP 24: STEP 25: Attach the 2 wiring harness retainers to the rear of the intake manifold. Connect the 8 fuel injector electrical connectors. Install the LH and RH fuel rail insulators. Install the RH heater hose support and the 2 nuts. Tighten to 7 Nm (62 lb-in). STEP 26: Install the vacuum tube assembly, the LH heater hose support and the 2 nuts. Tighten to 7 Nm (62 lb-in).
15 STEP 27: STEP 28: STEP 29: STEP 30: STEP 31: STEP 32: STEP 33: Position the heater hoses. Connect the vacuum tube to the intake manifold. Remove original fuel line and vapor line by disconnecting lines at rear base of left hand wheel well. Remove new lines from installation kit part number M-9444-M50B and connect line at rear base of left hand wheel well. Connect the fuel supply tube. Install the crankcase ventilation tube. Install the Evaporative Emission (EVAP) canister purge valve and bracket. (From kit part number M-9444-M50B) Note: Wiring for purge valve will have to be extended approximately 40 inches of 18 awg wire, cut and splice wire, solder and shrink tube. STEP 34: STEP 35: Connect the TB electrical connector. Remove old and install the Air Cleaner (ACL) outlet pipe. (From kit part number M-9444-M50B)
16 STEP 36: STEP 37: WARNING: Reconnect battery cable. Start vehicle and check for fuel and vacuum leaks. CUSTOM CALIBRATION REQUIRED! CALIBRATION NOT INCLUDED!
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