INSTALLATION MANUAL Applications RFI Part Number Ford 6.2L F250-F350 2011+ 51204-99 Not legal for sale or use in California on pollution-controlled vehicles.
Introduction This manual provides step-by-step installation instructions for the Bully Dog Rapid Flow Induction (RFI) Cold Air Intake for the 2011+ Ford 6.2L F250 and F350 trucks. Installation requires a few basic tools and takes about 20 minutes. Table of Contents Parts...1-4 Installation...5-14 Maintenance...15-16 Parts Included RFI Lid...(51200-1) MAF RFI Tube...(51201-3) Stage 2 RFI Tube...(51204-3) Air Filter with Band Clamp...(224900) 9.5 mm Silicone Hose...(51202-7) 16 mm Silicone Hose...(51201-6) Silicone Coupler 57 mm...(51200-5) Silicone Coupler 76 mm...(51200-6) #6 Hose Clamp (2)...(10800-2) #8 Hose Clamp (2)...(10800-4) 4 Worm Drive Band Clamp (4)...(51105-7) T20 Security Torx Bit...(229120) Black Oxide Phillips Screw (2)...(54100-94) Nylon Washer (2)...(51201-94) Zip Tie (2)...(1-NYTIE8) Tools Needed Flat-head screwdriver Phillips screwdriver 10 mm socket Bit Driver 1
Parts Description RFI Lid The easy-to-remove lid replaces the stock lid and allows for hassle-free filter maintenance. When the lid is installed, the OEM latches secure the lid to the box. RFI MAF Tube The RFI MAF tube comes with a precisely manufactured mount for the mass airflow (MAF) sensor. The mount has inset screw mounts that are designed to work with the black oxide screws provided by Bully Dog. The tube is also designed with a snap-fit feature that will secure it tightly to the RFI lid. Stage 2 RFI Tube Designed to fit in your engine bay, the stage 2 RFI tube improves air flow into the turbo through the smoothest curves possible to prevent any loss of power and provide sleek style under the hood. 2
Air Filter with Band Clamp The Rapid Flow Induction (RFI) Cold Air Intake system includes an ISO 5011 certified eight-layer oil filter. The air filter is housed within the intake enclosure and secured onto the end of the air intake tube using the included filter clamp and a flat-head screwdriver. Silicone Hose and Couplers The high quality 3-ply hose and couplers are durable, flexible and strong. Hose and Band Clamps Adjustable clamps connect and hold all tubing in place. 3
T20 Security Torx Bit The mass air flow sensor is attached to the stock intake tube using tamper resistant pin-in-torx screws. Bully Dog includes a Torx bit for convenience. If the bit is lost it can be purchased at any auto parts store. Black Oxide Phillips Screws Bully Dog provides screws to secure the mass airflow sensor to the MAF tube. Nylon Washers The nylon washers protect the mass airflow sensor and prevent it from being bent when it is attached to the MAF tube. Zip Ties Use the zip ties to secure parts within the engine bay. 4
Installation The RFI installation procedure can be separated into three parts: Removing the Stock Intake, Preparing the RFI Intake and Installing the RFI Intake. The diagram on the right shows how the parts of the RFI Cold Air Intake fit together in sequence. Removing the Stock Intake Band Clamp (3) Resonator Box CCV Tube (8) Brake Vacuum Tube (8) Coolant Overflow Hose (5) Mass Air Flow Sensor (2) OEM Intake Lid 1. IMPORTANT: Before beginning installation, disconnect your battery at the negative terminal. Failure to disconnect the battery could result in personal injury and/or damage to your vehicle. 5
2. Unplug the mass airflow sensor. Pull the red tab on the bottom of the plug to unlock it. Disconnect the sensor clip by pulling gently. 3. Loosen the band clamp on the resonator box. 4. Release the latches on the stock intake lid. 5. Unclip coolant overflow hose. 6
6. Remove the stock intake lid and tube. (You can take these out together as one piece.) 7. Remove the stock air filter. 8. Disconnect the CCV and brake vacuum tubes from the resonator box. Unclip the CCV tube. Pull the rubber brake vacuum tube off the box. 7
9. Detach the coolant overflow tube from the resonator box. Pull the tube away from the clips that secure it to the left side of the resonator box. Disconnect the two white barb connectors on the back of the resonator box. Tuck the tube back into a safe place while you complete the installation. 10. Remove the two bolts that secure the resonator box in the engine bay. (Use a 10 mm socket.) 8
11. Remove resonator box from the engine bay. 12. Loosen the band clamp connecting the resonator box coupler to the throttle body using a flathead screwdriver and remove the coupler. 13. Use the enclosed zip ties to secure the vacuum tube to the ECM cable harness. Don t pinch the vacuum tube. Clip the excess length off the zip tie. 9
Preparing the RFI Intake 1. Snap the RFI MAF tube into the RFI lid. 2. Install the air filter by connecting it to the RFI MAF tube. Connect it to the end of the tube that has been snapped into the RFI lid. Use a flat-head screwdriver to tighten the band clamp. 3. Remove the MAF sensor from the stock intake tube. (Use the included Torx bit.) 10
4. Attach the MAF sensor to the RFI MAF tube. Use the nylon washers and black oxide screws provided by Bully Dog. Use one washer on each side. IMPORTANT: Do not overtighten the screws, as this could damage the MAF sensor. 5. Connect the silicone couplers to the Stage 2 RFI tube. The long coupler connects with the RFI MAF tube. The short coupler connects to the throttle body. Put the band clamps on, but leave them loose. 6. Put the hose clamps on the silicon hoses, but leave them loose. Straight Silicone Hose 90 Silicone Hose 11
Installing the RFI Intake 1. Install the RFI lnstall the RFI lid/tube assembly. Line up the latch mounts on the lid with the latches on the stock intake enclosure. Close the latch 2. Install the Stage 2 RFI tube. Connect the silicone couplers to the RFI MAF tube and the throttle body. Connect the silicone hoses to the barbs on the Stage 2 tube as shown in the photo/diagram. 90 Silicone Hose Straight Silicone Hose 12
3. Swap the CCV tube and the brake vacuum tube with the included silicone hoses. Disconnect the stock tubes only when you are ready to install the silicone hoses. (This is easier than locating the connection at a later time.) 4. Tighten all of the band clamps after all of the parts are in place and connected correctly. (Use a flat-head screwdriver.) 5. Reconnect the MAF sensor plug and the battery. Make sure that the red tab on the sensor plug locks into place. 13
6. Start the vehicle, listen for leaks and check all connections. Go for a ride and enjoy. Be sure to check out the information about filter maintenance and the protective prefilter described in the next section. 14
Filter Maintenance The intake system should be cleaned with the Bully Dog RFI Cleaning Kit at least once every three months; in dusty climates, the filter should be cleaned more often. Cleaning the intake is a two part process: cleaning and oiling the filter. (1) Cleaning the Filter 1. Remove the filter from the RFI enclosure. Clean the enclosure if necessary. 2. Remove surface dirt (this step can be avoided if a Bully Dog RFI Prefilter has been installed). Lightly tap the filter. Use a soft-bristle brush to remove any loose particles. 3. Spray the cleaner generously over the filter and let it soak for 10 minutes. 4. Thoroughly rinse the filter. Use regular tap water. Avoid high-pressure hoses. Prevent dirt from entering the filter by rinsing from inside out or from the clean side to the dirty side. 5. Let the filter air dry. Do not use any method to speed up the drying process. Using a blow dryer or compressed air can disfigure the filter and allow particles to pass through. (2) Oiling the Filter Part# 229000 1. Apply a small amount of oil to the soft-bristle brush and gently spread the oil over the filter. Be sure to apply only a small amount of force so the filter is not damaged. 15
2. Continue applying the oil to the filter until the entire filter is covered in an even amount of oil. Apply enough oil to make the filter a solid and uniform blue, but do not go beyond that. 3. Allow the oiled filter to sit 20 minutes. Re-oil any dry spots that appear. Do not oil the filter excessively. Excessive oiling can cause damage to intake sensors. Prefilter The Bully Dog RFI Prefilter is a semi-waterrepellent barrier that will keep bugs and debris out while lengthening the time between filter cleanings and reducing the amount of time you spend cleaning the filter. 16
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Doc.# 51204-99 v1.3 Check out more of our ADRENALIN PUMPING products! Triple Dog GT Pre Filter Cleaning Kits Clothing GT Diesel is not legal for sale or use in California on pollution-controlled vehicles. Free Technical Support at: 1-940-783-9915 See More at: bullydog.com 19