Bill of Materials for 77060012 1 2-P5153572 Inlet Pipe 1 21-202M 2.75" Filter 1 103-BLO-4820N Filter Hose Clamp 1 559999 Washer, Fender M6x25 1 1-3028 Washer, 1/4 SAE Flat 1 1-2072 Bolt, 1/4-20-UNC x 1 3/4 1 1-2074 Lock Nut, '1/4-20 1 1-2073 Nut, '1/4-20 1 2-670 Spacer 1 5-257 Hose, Adapter 2.50/2.75" X3" 1 103-BLO-4420N 2.75" Hose Clamp 1 103-BLO-4020N 2.5" Hose Clamp 1 784634 Grommet,1/2" 1 10-77060012 Instructions 2 99024.032 Hose Clamp,1" 5" 65116 Hose,1/2ID Read and understand these instructions BEFORE attempting to install this product. 10-7706012 12/1/05 Page 1 of 8
1) Getting Started a) Make sure vehicle is parked on a level surface. b) Set parking brake. c) If engine has run with in the past two hours let it cool down. d) Disconnect the negative battery terminal. 2) Removal of the stock intake system a) Remove engine cover by pulling straight up. b) Twist and remove retaining clips. Remove ducting by pulling up and forward. c) Loosen hose clamp at the air box. 10-7706012 12/1/05 Page 2 of 8
INSTALLATION INSTRUCTIONS PART NUMBER 77060012 d) Loosen hose clamp of the inlet tube at the throttle body. e) Remove IAT (Intake Air Temperature) Sensor harness connector. Pull tab out, then depress clip. Inner housing f) Remove Christmas Tree Mount zip tie from inlet tubing. Remove inlet pipe. 10-7706012 g) Disconnect the crankcase breather hose from the valve cover. The other end will be connected to the air box. Unclasp the air box and remove the inner housing, air filter and breather hose. 12/1/05 Page 3 of 8
h) Pull up on the other half of the air box. Remove the air box. 3) Installation of the MOPAR Cold Air Intake System a) When installing the MOPAR Cold Air Intake System, DO NOT completely tighten the hose clamps or mounting tab hardware until instructed to do so later in these instructions. b) Attach the reducer coupler to the throttle body. Secure with the 2.5 hose clamp. Loosely attach the 2.75 hose clamp to the other side of the coupler. c) Insert grommet for the IAT sensor into the inlet pipe. 10-7706012 12/1/05 Page 4 of 8
d) Insert the all thread bolt with washer up through the air box mount grommet. e) Insert the spacer over the bolt. Secure the thread bolt with the provided nut. Center the spacer in the grommet and tighten. f) Insert the IAT sensor into the grommet from step 3c. g) Insert pipe as shown. Line up the bracket to the spacer assembly. 10-7706012 12/1/05 Page 5 of 8
INSTALLATION INSTRUCTIONS PART NUMBER 77060012 h) Insert the other end of the inlet pipe into the coupler at the throttle body. Realign the bracket and secure the hose clamp. i) Reattach the IAT sensor wire harness connector. Check for clearance around the negative battery terminal. j) Check for clearance of the inlet pipe around the coolant hose. Tighten bracket with washer and lock nut. k) Attach filter. Check for clearance and tighten with filter hose clamp. 10-7706012 12/1/05 Page 6 of 8
INSTALLATION INSTRUCTIONS PART NUMBER 77060012 l) Attach the breather hose as shown to the inlet pipe and to the crankcase vent. Secure with hose clamps. m) Secure both breather hoses with the factory clip. Reinstall the engine cover. n) Your Mopar Cold Air Intake System should look like this. 10-7706012 12/1/05 Page 7 of 8
4) Re-assemble the vehicle a) Position the filter for best fitment. Be sure that the filter, tube, or any other components do not contact any part of the vehicle. b) Tighten all hose clamps. c) Tighten the bolts and nuts on the mounting bracket. d) Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are tight. e) Reconnect the negative battery terminal. f) Start engine and perform a final inspection before driving the vehicle. 10-7706012 12/1/05 Page 8 of 8