Install Instructions for 76-1014

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Before You Start

Please read the entire installation instruction before proceeding. Ensure you have all the necessary tools to complete the installation. Ensure all parts are present. If you are missing any of the components, call our customer support at (909)947-0015. Do not work on your vehicle while the engine is hot. Make sure the engine is turned off and the vehicle is in Park or the Parking Brake is set. Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. 

Install Video Can Be Found Here.

Note: This intake elbow kit may not fit with the following aftermarket parts installed: Intercooler or Intercooler Pipe, Custom Hood, Intake Manifold

Post Installation Testing

After your installation is complete, engage parking brake and start your engine. It will take a little longer to initially start since the fuel pump will need time to refill the fuel rail and fuel lines. After the engine starts, listen for any abnormal noises.  If an air leak is detected, re-inspect hoses and bolted connections as they may need to be tightened and/or re-torqued to the correct value. Check for any fuel leaks and tighten and re-torque any leaking fuel lines. Take a short test drive of your vehicle and listen for any abnormal noises. Check again for any fuel leaks. Tighten and/or re-torque any loose connections. S&B FILTERS instructs that you keep your OE intake elbow and associated parts in the event it is required in the future. In order to maintain your warranty, periodically check the items listed in the Maintenance section. Failure to do so may void your warranty.

Maintenance

Periodically (during each engine oil change) Check the Following:

  •  Intake Air Heater electrical connection nuts (Item 16) making sure they are secure and tight.
  •  All electrical connections and wire harnesses moved during the installation of the intake and make sure they are secure and away from any hot or moving components.
  • Check for any signs of abrasion or wear and tear on the electrical harnesses moved or near the Intake Elbow and repair/replace as necessary.

Vehicle Fitment 2007.5-2018 6.7L Cummins Diesel, Ram, 2500/3500

Device Name: Cold Air Intake

Required Tools

Tools Required:

  • 8mm, 10mm, 13mm, 17mm, 24mm Socket and Wrench
  • 10mm, 11mm, 24mm Deep Socket and Wrench
  • 6” or 10” Wobble Socket Extension
  • 5/32” Ignition Wrench
  • 8mm Open/Box Combination Wrench
  • 13mm Open/Box Combination Wrench
  • 14mm Open Wrench
  • 19mm Open/Box Combination Wrench
  • 1” Open Wrench or Adjustable Open Wrench
  • 19mm Flare Nut Crowfoot Socket or 19mm High Pressure Fuel Line Socket
  • 24mm Open or Flare Nut Offset Wrench
  • 6mm Hex Bit Socket, ¼” Drive
  • 3” Socket Extensions, ¼” Drive
  • 6” Wobble Socket Extension, ¼” Drive
  • 1-¾” Socket Extension, ⅜” Drive
  • 3” Socket Extension, ⅜” Drive
  • 10” Socket Extension, ⅜” Drive
  • ⅜” to ¼” Step Down Socket
  • Universal Joint Adapter, ¼” Drive
  • Universal Joint Adapter, ⅜” Drive
  • T15 Torx Bit/Driver
  • Panel Popper
  • Flat Blade Screwdriver
  • Flush Cutter
  • Torque Wrench, ¼” Drive
  • Torque Wrench, ⅜” Drive
  • Snap-Blade Knife
  • Telescoping Magnetic Pickup Tool
  • Plastic Razor or Plastic Scraper
  • Heat Gun

Step 1A

With the ignition switched off and the parking brake set, disconnect the negative battery cables on both batteries. Disconnect the negative battery cable on the passenger side battery. Isolate the cable terminal from the battery by covering it with a rubber glove or other electrical insulating material.

Note: Failure to disconnect the battery for 2 hours may cause the CEL to illuminate upon completion of the installation and subsequent operation. DO NOT SKIP THIS STEP!

Tools Required: 8mm Socket/Wrench

Step 1B

Disconnect the negative battery cable on the driver side battery. Isolate the cable terminal from the battery by covering it with a rubber glove or other electrical insulating material.

Note: Failure to disconnect the battery for 2 hours may cause the CEL to illuminate upon completion of the installation and subsequent operation. DO NOT SKIP THIS STEP!

Tools Required: 10mm Socket/Wrench

Step 2

Remove the bolts securing the engine cover.

Tools Required: 8mm Socket/Wrench

Step 3

Remove the engine oil dipstick and then remove the engine cover.

Step 4

Replace the engine oil dipstick.

Step 5A

Disconnect the wire harness connector from the EGR temperature sensor located on the EGR crossover tube. If you have a 2007.5 to 2009 year model, your EGR temperature sensor may be located on the intake elbow as shown in Step 5B. To disconnect the harness connector, first slide to release the red locking tab, then depress the retaining tab and remove the connector from the sensor.

Step 5B

If you have a 2007.5 to 2009 year model, disconnect the harness from the EGR temperature sensor located on the back of the intake elbow. To disconnect the harness connector, first slide to release the red locking tab, then depress the retaining tab to remove the connector from the sensor.

Step 6

Remove the nut and T-bolt from the driver side V-band clamp on the EGR crossover tube.

Tools Required: 11mm Deep Socket/Wrench

Step 7

Remove the nut and T-bolt from the passenger side V-band clamp on the EGR crossover tube.

Tools Required: 11mm Deep Socket/Wrench

Step 8

Remove the coolant hose bracket bolt and move the coolant hose away from the engine and downward to allow more room to work in Step 9.

Tools Required: 10mm Socket/Wrench

Step 9

Remove the bolt holding down the EGR crossover tube bracket.

Tools Required: 8mm Socket/Wrench, 6” extension, ¼” Drive Universal Joint.

Step 10

Carefully open and move both V-band clamps away from the EGR crossover tube flanges being careful not to let the gaskets fall from either end of the EGR crossover tube.

Step 11

Place your hands underneath both flanges of the EGR crossover tube to make sure the gaskets don’t fall and carefully remove the crossover tube from the engine.

Step 11 Continued

Step 12

Note that the passenger side flange on the EGR crossover tube has a flat sealing surface and a flat metal gasket. Keep the gasket for re-use later.

Step 13

Note that the driver side flange on the EGR crossover tube has a conical sealing surface and a composite gasket. Keep the gasket for re-use later.

Step 14

Remove the P-clamp from the EGR crossover tube.

Step 15

Remove the wire harness retainers from the intake throttle shield and threaded stud.

Tools Required: Panel Popper

Step 15 (Continued)

Deburr the holes to prevent damage to the o-rings and apply paint to prevent corrosion once the 5/8" and 1/2" holes are drilled. Then, slide the coupler over the rear bar section with the larger coupler hole facing the outside of the truck and being on the same side as the 5/8" hole. You can use silicone lube or a grease to help the coupler slide if needed.

Step 16

Remove the wire harness retainer from the engine oil dipstick bracket threaded stud.

Tools Required: Panel Popper

Step 17

Disconnect the wire harness connector from the EGR valve by depressing the retaining tab and removing the connector.

Step 18

Remove the intake throttle shield threaded stud and bolt and then remove the heat shield. 

Tools Required: 10mm Deep Socket/Wrench, 13mm Socket/Wrench, 6” socket extension

Step 18 (Continued)

Step 18 (Continued)

Step 19

Loosen the Charge Air Cooler (CAC) hose clamp attached to the intake throttle. 

Tools Required: 11mm Deep Socket/Wrench, 6” socket extension

Step 20

Remove the bolt securing the engine oil dipstick tube.

Tools Required: 10mm Socket/Wrench, 6” socket extension

Step 21

Disconnect the wire harness connector from the TMAP sensor by depressing the retaining tab and removing the connector.

Step 22

Remove the wire harness retainer from the threaded stud on the back side of the intake elbow.

Tools Required: Panel Popper

Step 23

Remove the (6) bolts holding the intake elbow to the intake manifold.

Tools Required: 10mm Socket/Wrench, 10” Wobble Socket Extension, U-joint Adapter

Step 23 (Continued)

Step 24

Remove the intake elbow from the intake manifold and twist the elbow loose from the CAC hose. Do not attempt to completely remove the elbow from the engine bay until the harness in the following step, Step 25, has been disconnected.

Step 25

Carefully rotate the intake elbow to reveal the throttle wire harness connector. Disconnect the throttle wire harness connector. To disconnect the wire harness connector, first slide to release the red locking tab, then depress the retaining tab and remove the connector from the intake throttle.

Step 26

Remove the intake elbow from the engine bay. Mask the opening to the intake manifold and the CAC hose to prevent anything from falling in either location.

Step 26 (Continued)

Step 26 (Continued)

Step 27

Locate the wire harness bulkhead by the driver side firewall and remove the wire harness retainer.

Tools Required: Panel Popper

Step 27 (Continued)

Step 28

Rotate the latch to unlock and then separate the harness bulkhead.

Step 29

Disconnect the wire harness connector from the crankcase pressure sensor 1 located behind the crankcase breather cover on the driver side. To disconnect the harness connector, first slide to release the red locking tab, then depress the retaining tab and remove the connector from the sensor.

Step 30

Disconnect the wire harness connector from the crankcase pressure sensor 2 located on the passenger side of the crankcase breather cover. To disconnect the harness connector, first slide to release the red locking tab, then depress the retaining tab and remove the connector from the sensor.

Step 30 (Continued)

Step 31

Remove the wire harness retainer from the threaded stud located in front of the crankcase pressure sensor.

Tools Required: Panel Popper

Step 32

Disconnect both fuel injector wire harness connectors located on the driver side of the crankcase breather cover. To disconnect the harness connector, depress the retaining tab and remove the connector vertically upward. You can use a flat blade screwdriver to depress the retaining tab as you remove the connector.

Tools required: Flat Blade Screwdriver

Step 32 (Continued)

Step 33

Remove both CCV oil drain hoses located on the driver side of the crankcase breather cover. Carefully use a Panel Popper to push the end of the drain hose away from the hose barb.

Tools Required: Panel Popper

Step 34

Gently lift up and carefully remove the foam fuel rail silencer.

Step 35

Caution: Cleanliness cannot be overemphasized when handling diesel fuel system components. Always clean any fuel system component before disassembly. Before removing each diesel fuel line, clean them to remove any dirt and contaminants.

Step 36

Caution: When loosening or tightening the injector fuel line fitting, the connector nut must not be allowed to rotate. Damage to both fuel line and connector nut could result and cause a fuel leak. Make a line on both the connector nut and cylinder head to help you verify that the connector nut does not rotate.

Step 37

Loosen the cylinder #1 fuel injector line fitting at the cylinder head. Use a back up wrench to keep the connector nut from rotating when you loosen the fuel line fitting.

Tools Required: 19mm Open/Box Combination Wrench or 19mm Flare Nut Crowfoot Socket/Wrench or 19mm High Pressure Fuel Line Socket/Wrench, and 24mm Open or Flare Nut Offset Wrench

Step 38

Loosen the #1 fuel injector line fitting at the fuel rail.

Tools Required: 19mm Open/Box Combination Wrench or 19mm Flare Nut Crowfoot Socket/Wrench or 19mm High Pressure Fuel Line Socket/Wrench

Step 39

Remove the fuel injector line #1 and set it aside keeping it clean. Use shop towels to prevent or minimize fuel dripping down the side of the engine. Keep the fuel injector system clean by covering the fuel injector fitting at the cylinder head with the smaller diameter red colored Cap (Item 30).

Step 40

Keep the fuel injector system clean by covering the fuel injector fitting at the fuel rail with the larger diameter black colored Cap (Item 31).

Step 41

Repeat Steps 35 to 40 for each remaining fuel injector line, starting with fuel injector #2, then #3, then #4, then #5, and finally #6. Make sure you note the injector number on each fuel injector line so that you do not mix them up during re-installation. 


Note: To help gain access to the fuel injector #6 fitting at the cylinder head, disconnect the wire harness connector from the fuel rail pressure sensor. To disconnect the harness connector, first slide the yellow locking clip in the direction shown, second depress the retaining tab and third remove the connector from the sensor.

Step 41 (Continued)

Step 42

Loosen the fuel rail feed line fitting at the fuel rail and at the supply connection. Remove the fuel rail feed line and set it aside keeping it clean. Use a shop towel to minimize spilling fuel.

Tools Required: 19mm Open/Box Combination Wrench or 19mm Flare Nut Crowfoot Socket/Wrench or 19mm High Pressure Fuel Line Socket/Wrench

Step 43

Keep the fuel injector system clean by covering the fuel rail feed fitting at the fuel rail with the larger diameter black colored Cap (Item 31) and the supply connection fitting with the smaller diameter red colored Cap (Item 30).

Step 43 (Continued)

Step 44

Start to remove the electrical wire harnesses from around the fuel rail. First undo the clip holding the harness to the oil dipstick tube. Push the opposing interlocking tabs away from each other to release the clip.

Step 45

Disconnect the wire harness retainers from the fuel rail mounting studs. Pull off the retainers from the threaded studs.

Tools Required: Panel Popper

Step 46

Disconnect the wire harness connector from the manifold temperature sensor located near the back end of the fuel rail. To disconnect the harness connector, first slide the red locking clip, then depress the retaining tab and remove the connector from the sensor.

Step 47

Disconnect the wire harness connector from the EGR bypass valve located by the passenger side of the cylinder head. To disconnect the harness connector, first slide the red locking clip, then depress the retaining tab and remove the connector from the sensor.

Step 48

Disconnect the wire harness connector from the exhaust pressure sensor located next to the EGR bypass valve. To disconnect the harness connector, first slide the locking clip, then depress the retaining tab and remove the connector from the sensor.

Step 49

Carefully drape the entire harness from Steps 29 to 32 and Steps 44 to 48 over the driver side fender to give full access to the fuel rail.

Step 50

Remove the grid heater cable nut and the heater cable from the stud.

Tools Required: 10mm Socket/Wrench

Step 51

Remove the fuel return line banjo bolt and carefully remove the sealing washers from both sides of the banjo fitting. If the seal on the sealing washers is damaged, replace with new sealing washers before re-installation.

Tools Required: 17mm Socket/Wrench

Step 51 (Continued)

Step 51 (Continued)

Step 52

Remove the bolts and threaded studs that hold down the fuel rail. Note the locations of the bolts vs the threaded studs for re-installation of the fuel rail.

Tools Required: 10mm Deep Socket/Wrench

Step 53

Carefully remove the fuel rail from the engine bay and set it aside somewhere clean.

Step 54

Remove the bolts and threaded stud that hold down the intake manifold cover. Note the locations of the bolts vs the threaded stud for re-installation.

Tools Required: 10mm Deep Socket/Wrench