Install Instructions for 75-5100

Step 1

With the ignition switched off and the parking brake set, disconnect the negative battery cable on the battery.

IMPORTANT: Failure to disconnect the battery for a minimum of 2 hours may cause the Check Engine Light to illuminate upon completion of the installation or subsequent operation.
DO NOT SKIP THIS STEP!

Tool Required: 10mm Socket/Wrench.

Step 2

Remove the two nuts securing engine cover then lift up and remove the engine cover from the vehicle.

Tool Required: 10mm Socket

Step 3

Disconnect the MAF sensor electrical connector from the sensor.

Step 4

Disconnect the breather and vacuum hoses. Remove the two mounting screws on the intake box. Loosen the hose clamp on the throttle body. Pop-out the wire harness clip.

Tool Required: 10mm Socket/Wrench, Panel Removal Tool

Step 5

Locate the smog pump by the stock intake tube and remove the cover by pulling out the tabs on the side and lifting up.

Step 6

Disconnect the electrical harness and hose from the smog pump.

Tool Required: Panel Removal Tool, Pliers

Step 7

Remove the three bolts securing the smog pump bracket then remove the smog pump and bracket assembly from the vehicle.

Tool Required: 10mm Socket/Wrench

Step 8

Remove the two screws securing on the stock tube then remove the entire air intake assembly from the vehicle. Set the screws aside. One will be reused in Step 11 to install the smog pump bracket and the other in Step 24 to install the Intake Box (A).

Tool Required: 12mm Socket/Wrench

Step 9

Locate the mounting hole in between the radiator cap and passenger side headlights. Carefully look at the smog pump brackets in the exploded view. Each one has its own distinct shape. Install the 5.6” Smog Pump Bracket (U) into the mounting hole with the M6 Bolt (V), M6 Washers (W), and M6 Locknut (X). Keep the bracket as horizontal as possible then tighten the bolt and lock nut.

Tool Required: 10mm Socket/Wrench

Step 9 (Image 2)

Step 10

Locate the power steering reservoir. There are two mounting locations you will use to secure the last two smog pump brackets. Remove the bolt closest to the front of the vehicle and slide the 8.3” Smog Pump Bracket (T) underneath. Loosely tighten the bolt so you can make final adjustments in a later step.

Tool Required: 10mm Socket/Wrench

Step 10 (Image 2)

Step 11

Install the 6.4” Smog Pump Bracket (S) at the second mounting hole with the bolt removed in Step 8.

Tool Required: 12mm Socket/Wrench

Step 12

Apply even pressure and carefully pull the grommets out of the smog pump arms. Be careful not to damage the grommets. Perform the same steps for the other two grommets then remove the smog pump from the bracket.

Step 13

Apply even pressure and carefully slide the grommets out of the bracket. Be careful not to damage the grommets because they will be reused and installed onto the three Smog Pump Brackets (S, T, and U).

Step 13 (Image 2)

Step 14

Connect the Smog Pump Harness Extension (Y) into the stock harness. Route the harness behind the washer fluid reservoir and place the harness by the smog pump brackets.

Step 14 (Image 2)

Step 15

Route the harness underneath the smog pump and connect the harness into the smog pump connector. Install the smog pump onto the grommets.

Step 15 (Image 2)

Step 16

Rotate the smog pump hose at the engine inlet until there are no kinks and reconnect the hose into the smog pump.

Tool Required: Pliers

Step 17

Reinstall the smog pump cover.

Step 18

Remove the two brackets securing the AC line hose clips. Remove the bolt mounted to the chassis on each bracket. Only the bolt from the left AC line bracket will be reused in Step 30. Remove the lock nuts securing both the rubber spacers to the hose clips. Once everything is removed, install the rubber spacer with the AC line clips into the chassis and tighten with one of the locknuts removed.

Tool Required: 10mm Socket/Wrench

Step 18 (Image)

Step 19

Pop-out the three plastic clips. One of the holes will be used to secure the Intake Box (A) in Step 23.

Tool Required: Panel Removal Tool or Pliers

Step 20

Install the Intake Tube Seal (D) onto the Intake Box (A).

Step 21

Install the Fender Seal (B) onto the Intake Box (A).

Step 22

Place the Intake Box (A) into the truck.

Step 23

Reinstall the stock screws removed from Step 5 to secure the Intake Box (A). Install an M6 Locknut (R) on the bolt with the hole that is not threaded. Make sure that the bolt goes through the hole through the wheel well cover before installing the locknut from underneath the wheel well.

Tool Required: 10mm, 12mm Socket/Wrench

Step 23 (Image 2)

Step 24

Carefully remove the MAF sensor from the stock intake tube. Use the supplied 8-32 Screws (K), MAF Plate (M), MAF Gasket (L) to install the sensor onto the Intake Tube (E). Install the Vacuum Hose Barb (J) until finger tight, then turn it one to two complete turns with a wrench. Do not over tighten.

Tool Required: Adjustable Wrench, 8mm Socket/Wrench, Screwdriver

Step 24 (Image 2)

Step 25

Install the Coupler (F) and two #52 Hose Clamps (G) onto the intake tube. Leave both hose clamps loose, push coupler up the tube slightly.

Step 26

Place the Air Filter (C) into the Intake Box (A). by first having the filter top facing the front of the vehicle then sliding it in, then turn the filter to the tube outlet. The air filter should be in the same position as shown below when inserting into the intake box.

Step 27

Insert the Intake Tube (E) through the Tube Seal (D) into the Intake Box (A) then slide the Air Filter (C) onto the intake tube. Tighten the #80 Hose Clamp (H).

Tool Required: 8mm Socket/Wrench

Step 28

Remove the stock vacuum hose and use the Vacuum Hose (N) provided to connect the Vacuum Hose Barb (J) and the engine.

Step 29

Install the Intake Tube (E) onto the throttle body. Tighten the #52 Hose Clamp (G) at the intake tube only. Leave the hose clamp at the throttle body loose. Reconnect the Breather Hose. Reconnect the MAF sensor connector into the MAF sensor. Cut the electrical tape at the main harness to give the connector extra slack and route the connector underneath the Intake Tube to connect into the sensor.

Note: If you want to reinstall the engine cover, align the insert on the intake tube with the two mounting points on the engine cover. Make any adjustments to the intake tube if necessary then tighten the #52 Hose Clamp (G) at the throttle body.

Tool Required: 8mm Socket/Wrench

Step 29 (Image 2)

Step 30

(OPTIONAL) Reinstall the engine cover. Reuse the nut removed in Step 2 and screw removed in Step 18. You may have to rotate the tube for the threaded insert to line up properly. Note: You will have to break off the small tap on the bottom of the engine cover on the passenger side so the engine cover sits flush with the intake tube.

Tool Required: 10mm Socket

Step 31

Press the Lid Seal (I) into the grooves on top of the Airbox (A).

Step 32

Remove the protective covering on the Clear Lid (Q).

Step 33

Install Clear Lid (Q) on top of the Airbox (A) with the 1/4-20 Screws (O) and Washers (P).

Tool Required: Screwdriver

Step 34

Reconnect the negative battery cable. Inspect your installation, make sure the kit is properly positioned and all fasteners are secured. Keep all stock parts in case you would ever need to reinstall the stock intake assembly. Affix the ID label near the intake kit. The installation is now complete.