Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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INSTALLATION INSTRUCTIONS 1. REMOVE AIRBOX SCOOP – - Remove two plastic body clips with Phillips head screwdriver Gently pull scoop away from airbox 2. REMOVE AIRBOX MAF Sensor – Disconnect MAF sensor plug and loosen hose clamp – - Remove 10mm bolt connecting airbox to bracket Remove entire airbox and MAF assembly by gently pulling up and away from the factory rubber intake pipe Remove BPV (Turbo Bypass Valve) return hose from IC to BPV Remove BPV from rubber intake pipe and completely disconnect BPV vacuum line – - 3. – - – - REMOVE RUBBER INTAKE PIPE FROM TURBO Loosen hose clamp from intake pipe to turbo Remove boost solenoid hose from intake pipe (leave connected to solenoid) Remove crank case vent line (take off completely) Pull intake pipe away 4. REMOVE MAF SENSOR FROM STOCK AIRBOX AND INSTALL TO HARMAN INTAKE PIPE. BE CAREFUL NOT TO PINCH OR DAMAGE THE RUBBER O-RING ON THE MAF SENSOR. Use supplied 4mm bolt with lock washer and washer to attach MAF sensor to intake pipe. DO NOT OVERTIGHTEN. 5. INSTALL 3.00” TO 2.75” SILICONE REDUCER TO TURBO WITH SUPPLIED CLAMP. Small side goes to the turbo. 6. INSTALL HM INTAKE PIPE TO SILICONE REDUCER WITH CLAMP CONNECT MAF SENSOR PLUG TO MAF SENSOR 7. This is the most common problem when installing the intake. Don’t forget to plug in the MAF sensor before turning the ignition. Failure to do so will cause a CEL. 8. INSTALL CONE FILTER USING SUPPLIED HOSE CLAMP 9. INSTALL BPV

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2) Removing the stock air inlet system a) Before removing any of the O.E. components, label each individual part so that no components become mixed up during the installation process. b) Remove plastic intake duct from the front of the engine by removing the plastic clips and pulling the duct straight forward. To remove the clips, use a pointed device and push in the middle of the clips. Throttle Cable c) Remove the breather hose from the valve cover by pulling it off. d) Unclip the throttle cable from the side of the air filter housing. 3 e) Unclip the Mass Air Flow (MAF) sesnor wiring harness from the air filter housing. These clips can be removed undamaged from the harness using a small flat head screwdriver. f) Unscrew the Inlet tube from the throttle body and pull the inlet tube off the throttle body. g) Unplug the MAF sensor from the engine harness. h) Remove the two bolts securing the stock air filter housing to the engine bay. Remove the air filter housing and the inlet tube. i) Remove the two bolts securing the MAF sensor to the air filter housing and remove the MAF sensor. Be careful not to damage the sensor. j) Unclip the wiring harness from the air box bracket behind the batery.

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1) Getting started a) b) c) d) Make sure vehicle is parked on a level surface. Set parking brake. Disconnect negative battery terminal. If engine has run within the past two hours let it cool down. 2) Removing the stock air inlet system Push in and remove. Clip a) Push in clip on the center circle to remove. Remove both clips. Remove inlet duct to air box. b) Locate the 4 clips on each corner of the air box. Remove c) Unfasten the 4 clips that hold down the top to the air box. Remove top. 3 Loosen only. Remove d) Remove the filter element. Remove the bolts holding down the bottom portion of the air box. e) Loosen the hose clamp connected to the bottom portion of the air box. NOTE: Do not loosen the worm gear type hose clamp located on the charge pipe. Loosen and remove. Unplug. f) Disconnect the MAF sensor harness from the bottom portion of the air box. Carefully remove the bottom portion of the air box. The honeycombs in the MAF sensor are sensitive, take note not to damage during removal. g) Carefully remove the 4 bolts holding the MAF sensor to the bottom portion of the air box. Check the MAF sensor gasket for tears or cracks. Replace as necessary. h) Loosen the hose clamp connecting the blow off valve to the turbo inlet hose. Disconnect the blow off valve from the inlet hose. Remove hose clamp from the inlet hose. Loosen and remove. 4 Disconnect. Loosen hose clamp i) Loosen the hose clamp on the turbo inlet hose at the turbo. This double ring clamp is similar to the clamp in step f. j) Disconnect the crankcase breather tube at the turbo inlet hose. Remove k) Disconnect vacuum line from the boost solenoid to the turbo inlet hose. The vacuum line is located underneath the turbo inlet hose. Remove the turbo inlet hose.

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Some 2003-2004 F-Super Duty and Excursion vehicles equipped with the 6.0L engine built on or before 9/29/2003 may experience a P006A or P132B Diagnostic Trouble Code (DTC) with a lack of power condition, surge, or turbocharger flutter after performing Field Service Action (FSA) 06E17, or after recalibrating the vehicle with the inferred Exhaust Pressure (EP) strategy. ACTION This procedure is to be used only on vehicles that have received the inferred EP calibration update. There are a variety of reasons why a customer could experience a lacks power condition with the inferred EP calibration. These can include causes a person may not directly see as impacting the condition or codes set. For example; a Mass Air Flow (MAF) / Manifold Air Pressure (MAP) code can be related to a MAF sensor or a MAP sensor problem. However, those codes can be caused by other items such as: intake leaks, exhaust leaks, Exhaust Gas Recirculation (EGR) problems, and aftermarket modifications. Care should be taken to follow the entire procedure outlined below. Skipping a step may lead to being unable to properly diagnose one of these other conditions setting a code. SERVICE PROCEDURE

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Initial disassembly 1. Disconnect the battery. Remove battery and the battery tray. 2. Using floor jack, elevate front end and place securely on jack stands. 3. Drain the coolant from the radiator. Capture and save for re-use. 4. Remove both upper and lower radiator hoses. 5. Remove front bumper. 6. Remove both headlights. 7. Remove steel inner bumper. 8. Remove the entire air cleaner assembly, including housing, ducting, and the MAF sensor. 9. Disconnect and remove horns. 10. Remove dipstick and dipstick tube. 11. Remove exhaust manifold. Remove oxygen sensor from manifold for reuse. 12. Loosen alternator tensioner and remove alternator belt. 13. Remove power steering pump belt and then pump (Note: Do not remove lines from pump, lay pump over towards inner fender). 14. Remove power steering pump bracket. 15. Remove bracket holding wires to Crank Position Sensor and Oil Temp Sensor. Cylinder head removal/installation NOTE: THIS PROCEDURE DOES NOT INCLUDE DETAILED INSTRUCTIONS FOR THE REMOVAL/REPLACEMENT OF MAJOR COMPONENTS. PLEASE REFER TO THE MANUFACTURERS SERVICE MANUAL. 1. Remove all electrical connections from the intake manifold. This includes disconnecting all sensor plugs from the throttle body and manifold, removing the fuel injector wiring harness, removing the ground strap, and disconnecting the knock sensor. 2. Disconnect the throttle and cruise control cables from the throttle body and lay cables to sides of engine bay. 3. Disconnect the fuel rail supply hose. Remove fuel rail, complete with injectors. 4. Disconnect the hose from the EVAP canister to the manifold, and unclip canister from manifold.