Install Instructions for 76-7015

Before you Begin

This installation requires the use of a powered electrical busbar found underneath the hood of the vehicle. The provided Wire Harness (J) is designed to work with these factory-installed electrical posts on the busbar and has the length of wire necessary to power the Particle Separator's scavenge fan anywhere on the vehicle. If the busbar in your vehicle is not connected to the vehicle's battery do not begin the installation of the Particle Separator. You will need to install both a power and a ground cable from the vehicle's battery to the busbar. 

Step 1

Remove the three panel retainers on the rear shroud.

Tools Required: Panel Removal Tool

Step 2

Disconnect the rubber intake tube from the OEM side cover.

Step 3

Remove the 6 panel retainers on the frogskin side cover.

Tools Required: Panel Removal Tool

Step 4

Disconnect the hose clamp on the bottom of the rubber intake tube and remove the tube.

Tools Required: 6mm Socket

Step 5

Remove the two screws attaching the side panel to the frame.

Tools Required: Phillips #3 Screwdriver

Step 6

Find HP1728-00 and install the One Way Valve (28) into the Side Cover (7).

Step 7A

Find the two Side Cover Mounting Brackets (26) and two M6 x 1.0 Button Head Cap Screws (27) with two black M6 Washers (29) in HP1728-00. Attach the two brackets to the Side Cover AL1381-00 (7).

Tools Required: 4mm Hex Key

Step 7B

Step 8

Install the Side Cover (7) onto the stock panel, pushing four of either the stock or supplied Panel Retainers (30) into the Side Cover.

Step 9

Install either the supplied M6 x 1.0 Button Head Cap Screws (27) or the stock screws into the Side Cover Mounting Brackets (26) to hold down the Side Cover.

Tools Required: 4mm Hex Key or Phillips #3 Screwdriver

Step 10

Find AI1523C-00 (8) and two of the four supplied Black #72 Hose Clamps (4). Install the coupler and hose clamps loosely onto the side cover as shown. Ensure the drive portion of the hose clamps is not in a location where the rear cover will interfere with them.

Tools Required: 5/16” Nut Driver/Socket

Step 11

Find the intake tube AL1380-00 (6) and the coupler AI1601C-00 (9). Install the two #52 hose clamps (5), tightening the upper one onto the tube.

Tools Required: 5/16” Nut Driver/Socket

Step 12

Install intake tube AL1380-00 (6) onto the airbox inlet and into the AI1523C-00 (8). Tighten all hose clamps.

Tools Required: 5/16” Nut Driver/Socket

Step 13

Remove the 6 panel rivets and 2 Phillips head screws from the front console of the vehicle.

Tools Required: Panel Removal Tool and Phillips #3 Screwdriver

Step 13B

Step 13C

Step 14

Remove the cover and disconnect the two switches by pushing the retaining tab down.

Step 15

Remove the two nuts holding down the 12 volt switched power and ground connectors.

Tools Required: 10mm Socket

Step 16

Connect the BATT cable (red) and ACC cable (Orange) from the Main Wire Harness (23) to the power connector and the GND cable (Black) to the Ground connector. **Note** Some models have constant power, switched power, and ground at the bus bar. If so, connect BATT to constant power, ACC to switched power, and GND to ground.

Tools Required: 10mm Socket

Step 17

Reinstall the covers over the electrical connections.

Step 18

Find the Ignition Sensor Assembly (24) and install it onto the upper coil wire as shown. Try to install the sensor so the insulation is not wrapped into the sensor’s jaws.

Tools Required: Phillips #2 Screwdriver 

Step 19

To ensure all electrical components are working properly, find the Control Board Harness (25) and connect it to the Particle Separator (1) and to the Ignition Sensor Assembly (24) and the Main Wire Harness (23). Follow the below steps to run a test to verify the function of the whisper quiet fan technology system:

1. Turn the ignition to the key on position. The fans on the particle separator should be at 20% speed and should barely be audible.
2. Turn the ignition on. The fans should be at 50% speed and barely be audible over the engine idle noise.
3. Rev the engine to a constant 4000 rpm for 5 seconds and then take your foot off of the gas. The fans should build to and stay at max speed during the 5 seconds, and decelerate back to 50% speed shortly after you let your foot off of the gas. Your electrical components are all working correctly if your particle separator behaves as these tests describe. If the separator does not act as described, please watch our electrical system troubleshooting video to determine the cause of the misbehavior.

Step 20

Install the Clamp Straps (14) to the upper rear roll bar approximately 25 inches apart. Using plastic to wrap the bar will help prevent any scratches.

Step 21

Install the Pivot Body (13) into the Clamp Strap (14) using the long M8 Button Head Cap Screw (16) , two M8 Washers (15), and Nylon Lock Nut (18). Leave the M8 bolts loose.

Tools Required: 5mm Hex Key and 13mm Socket

Step 22

Install the Clamp Adapters (11) to the separator unit using two M6 Button Head Cap Screws (19) and Washers (20). Apply the blue thread locker to the screws.

Tools Required: 4mm Hex Key

Step 23

Install the Clamp L Bracket (12) to the Clamp Adapters (11). A dry fit to the Pivot Body (13) for angle and position verification may be helpful. Once settled upon, apply blue thread locker and tighten down the short M8 Button Head Cap Screw (17) and Washer (15).

Tools Required: 5mm Hex Key

Step 24

Install the Clamp L Bracket (12) to the Pivot Bodies (13), using a Washer (15) and having applied blue thread locker to each shortM8 Button Head Cap Screw (17). Tighten all bolts including those on the clamp straps.

Tools required: 5mm Hex Key

Step 25

Find the Flexible Duct (2) and align it between the Particle Separator Outlet (1) and the Side Cover (7). Cut the duct to length with a razor knife and wire cutters.

Tools Required: Razor Knife and Wire Cutters

Step 26

Find the Flexible Duct End Cuffs (3) and the other two Black Hose Clamps (4), assemble them loosely onto the flex duct.

Step 27

Install the Flexible Duct (2) onto the outlet of the separator and the inlet of the side cover as shown.

Step 28A

Install the Control Board Harness (25) onto the roll cage with Zipties (10) and plug it into the Particle Separator (1) unit.

Step 28B

Step 28C

Step 29

Route the Ignition Sensor Assembly (24) up to the Control Board Harness (25) and connect it. You may wish to secure it alone to the roll cage, or wait to secure the Main Wire Harness (23) with it.

Step 30A

Route the Main Wire Harness (23) from the busbar back to its connection point on the Control Board Harness (25). It is not necessary to remove the center console and other panels, but doing so allows the wiring to follow the stock path and attach to the stock cable management. The removal process is fairly involved.

Tools Required: Panel Removal Tool and Phillips #3 Screwdriver

Step 30B

Step 30C

Step 31

Bundle the excess cable and relay, and mount them to the busbar support with the provided Zipties (10).

Step 32

Reinstall the rear cover.

Step 33

Reinstall the Rear cover.

Step 34

You have now completed the installation for your new Particle Separator. To ensure that everything is installed correctly and there are no problems with any part of the electrical system, we need to run a test to verify the function of the whisper quiet fan technology system. 

Test the particle separator with these steps:

1. Turn the ignition to the key on position. The fans on the particle separator should be at 20% speed and should barely be audible.
2. Turn the ignition on. The fans should be at 50% speed and barely be audible over the engine idle noise.
3. Rev the engine to a constant 4000 rpm for 5 seconds and then take your foot off of the gas. The fans should build to and stay at max speed during the 5 seconds, and decelerate back to 50% speed 2 seconds after you let your foot off of the gas.

If your particle behaves as these tests describe, the installation is complete. If the separator does not act as described, please watch our electrical system troubleshooting video to determine the cause of the misbehavior.