COLD AIR INTAKE KIT
2003-2007 Ford 6.0L Powerstroke Diesel Pickup Truck
CAUTION!!! Never work on a hot vehicle. Serious injury in the form of burns can
result if the vehicle has been in use. Allow vehicle to cool prior to installation.
Always wear eye protection when working on or under any vehicle.
Note: For your safety we recommend disconnecting any negative battery terminals
whenever working on any vehicle.Installation of the Cold Air Intake requires removal
of the plumbing to the turbo intake. Use caution not to get any dust, debris, or tools
left where they may enter the system.
Note: Prior to installation, please compare the parts that you have received with the
bill of materials listed above to ensure that you have all the necessary parts for
installation.
COLD AIR INTAKE KIT
INSTALLATION INSTRUCTIONS
PACKING INCLUDE
PACKING INCLUDE
1 X Cold Air Intake Tube
1 X Filter w/Hose Clamp
2 X Hose Clamp
1 X Intake Tube Support Bracket
1 X Silicone Coupler
1 X Silicone PCV Hose
2 X O-Ring
1 X 90 Degree PCV Fitting
1 X Straight PCV Fitting
1 X M8x15 Bolt and Flange Nut
2 X Bolts
1 X Allen Wrench
WARNING
Step 1: Remove the factory air filter. Release the clips, then pull the front and rear
covers up and away from the filter. Pull the filter straight up and out of the vehicle.
Note: The covers interlock to the bottom of the filter. Pulling out and up releases
them.
Step 2: Disconnect the MAF sensor plug.
Step 3: Remove the two hard plastic covers for the filter from the vehicle. The
rear cover is secured by a hose clamp. Use an 8mm socket or a regular screw
driver to release it.
Note: Remove the rubber hose that is attached to the front cover from the
vehicle as well.
Step 4: Loosen the hose clamp securing the stock intake to the turbo.
Step 5: Remove the two 10mm nuts securing the intake bracket to the fuel injection
control module. Then disconnect the PCV tube from the valve cover.
Note: The bracket and PCV tube are located behind the intake tube in
image.
Step 6: Remove the remaining factory intake tube from the vehicle.
COLD AIR INTAKE KIT
INSTALLATION INSTRUCTIONS
02
Step 7: Install the silicone connecting tube to the turbo intake using one of the supplied
hose clamps.
Step 8: Install the PCV adapter to the valve cover. If your valve cover doesn’ t have a
plastic box attached to it, use the included 900 adapter.
Note: In step 9, you may need to cut the silicone hose to fit. Years 03-04
with no plastic box attached to the valve cover,leave the hose 6 1/2” long.
Step 9: Connect the supplied silicone tube to the PCV adapter. Years 05-07 cut the
hose to 4 3/4”
Step 10: Using the supplied security torx tool, transfer the MAF sensor from the factory
intake to the new intake. Then install the intake support hand tight.
Step 11: Install the Cold Air Intake into the vehicle with the remaining hose clamp.
Connect the PCV silicone tube to the intake, and reconnect the MAF sensor.
Note: The silicone PCV tube is a press on fitting and doesn’t use any clamps.
Step 12: Secure the intake support by inserting the end into the factory rubber mount-
ing grommet. Then tighten the mounting bolt.
Step 13: Place the supplied filter onto the intake. Be careful not to tear the filter on any
sharp edges in the vehicle. Secure the filter with the supplied hose clamp.
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COLD AIR INTAKE KIT
INSTALLATION INSTRUCTIONS
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