Includes: 1. Silicone Hose 2. EGR Block Off Plates 1. Exhaust Block Off Plate 2. Hose Clamps 1. Spacer/Washer 8. Bolts 2. Nuts
WARNING: This product is not legal for sale or use on pollution controlled vehicles and is sold ONLY for off-road competition race use only. It is not for sale or use in CARRB regulated areas. This product cannot be used on highway registered vehicles. By purchasing this product, you agree to use it in conform too local, state, and federal laws. The purchaser of this product is responsible for misuse of the product. CAUTION: Never work on a hot vehicle. The hot exhaust system or hot engine can cause serious injury in the form of burns. If the vehicle has been in use or the engine was running and the exhaust system or engine is hot, allow the engine to cool for a minimum of one hour prior to starting the job. Always wear eye protection when working on or under the vehicle. Before removing any of the original parts from your vehicle, please compare the parts you have received with the picture and parts list of the kit you ordered. This assures that you have all the parts necessary for the installation. Prior to disassembly, we suggest applying penetrating fluid, such as PB-Blaster or JB-80 to all exhaust fasteners. Before working on the vehicle, be sure it is parked on a level surface and is chocked to prevent the vehicle from rolling. Please also be sure the keys are removed from the vehicle for your safety. 1: Disconnect the batteries. 2: Drain the engine coolant into a clean catch pan. Remove the passenger side inner wheel well and disconnect the lower radiator hose. You will have to remove the metal clip. Do not pull the hose all of the way off, just enough to drain the coolant. When the overflow bottle is empty, reconnect the lower radiator hose. 3: Loosen the hose clamps on the intake and disconnect the MAF sensor.
4: Remove the intake tube that is routed from the air filter to the turbo mouthpiece. 5: Gently pry out the three rubber grommets that hold the air filter box in place. 6: Remove the intake resonator on the top of the engine by loosening the hose clamp at the base of the resonator and loosening the long bolt on the front of the resonator box. 7: Disconnect the large charge wire on the alternator, and remove the plastic clip that holds the wiring harness to the plastic wire way. 8: Open the plastic housing on top of the intake grid heater and disconnect the power wire. 9: Loosen the two bolts and one nut that secure the plastic wire way in place. 10: Disconnect the wire connector on the front of the intake grid heater, and remove the bolt that secures the connector wires to the side of the intake tube. 11: Also remove the plastic clip that is holding the wire in place. 12: Remove the metal retaining clip located on the front passenger side of the plastic intercooler piping, and disconnect the plastic tube from the cast aluminum intake tube. 13: Remove the wire connector and the four bolts that hold the forward section of the cast intercooler piping onto the intermediate section. On the bottom of the front piece, there is a fifth bolt that secures the intake to a support bracket. 14: Remove the forward piece of the cast intercooler tube along with the plastic intercooler piece that connects it to the intercooler.
15: Remove the small plastic/rubber tube that is attached to the cast intake next to the intake grid heater. 16: Remove the four nuts and two bolts that hold the main section of the cast intake tube in place. Two bolts are on the back side of the large section of the cast intake. 17: Remove the PCV tube from the driver and passenger side valve covers also remove it from the turbo mouthpiece. 18: Remove the turbo mouthpiece by loosening the hose v-clamp that holds it to the turbo. 19: Disconnect the coolant lines that are running to the EGR cooler. Then remove the coolant lines. 20: Remove the EGR cooler & Valve, secured by five bolts. Three are at the back of the cooler. Two bolts are facing forward holding the EGR cooler to the turbo up pipe and one support bolt holds the EGR cooler to the engine. There are also two rear facing bolts are at the front of the cooler. Be sure to save the exhaust up pipe gasket for installation. 21: Install the new exhaust block off plate using the factory gasket and the supplied hardware. (Red RTV or a new gasket may be necessary if the factory gasket is worn.) Two M8 hex head bolts will bolt in from the back and one M10 fine thread hex head bolt will hold the support bracket in place. Note: If this support bracket does not align do not force it! You will need to make the hole larger. Forcing the up pipe to align with the bolt hole will cause the bellow to crack on the EGR riser. 22: Using the supplied hose clamps, install the new silicone hose from the port on the firewall to the port near the thermostat housing. Both of these ports previously had coolant lines that ran to the EGR cooler.
23: Install the two aluminum block off plates onto the bottom of the intake manifold where the EGR valve was originally mounted using two 20mm allen bolts and two 30 mm allen bolts supplied. Note: The 30mm (long) allen bolts are placed on the front side. 24: Install the support bracket where the EGR valve was using the supplied hardware. The spacer goes underneath the support bracket on the M10 x 20 hex head bolt. The bracket also uses a factory bolt which was removed earlier. 25: Reinstall the cast intake elbow to the engine. Align the long allen bolts into the support bracket. Using the two flange nuts secure the intake elbow to the support bracket. Then reinstall the cast elbow by reversing the removal steps. 26: Re-install the plastic mouthpiece to the turbo and the PCV tube. 27: Reconnect the charge wire to the top of the alternator, and use the plastic clip to hold wiring harness to the plastic wire way. 28: Install the intake resonator box on top of the plastic turbo mouthpiece, and secure it with the hose clamp on the bottom and the long bolt at the front of the resonator box. 29: Re-install the air intake and plug in the mass airflow sensor. 30: Make sure everything is tight and reinstalled. Now refill the vehicle with coolant. Then reconnect the batteries. 31: Start the engine, and check for leaks. If no leaks are present, let the engine run until the coolant circulates. Then, top off the coolant as needed. Congratulations on your installation!
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