Install Instructions for 76-1014 (Part 2)

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Before You Start

This is the 2nd Part of the Install Instructions

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 Dodge Ram 2500/3500 6.7L Cummins Diesel

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
  • 90 degree hook/pick

Step 129

Using a Flush Cutter, cut and remove the second retaining clip on the EGR valve and temperature sensor harness. Be careful not to damage the wire harness.

Tools Required: Flush Cutter

Step 130A

Attach the EGR Valve Extension Harness (Item 34) to the EGR valve. Fully insert the connector until the retaining tab “clicks” into place.

Step 130B

Attach the other end of the EGR Valve Extension Harness (Item 34) to the stock EGR wire harness. Fully insert the connector until the retaining tab “clicks” into place.

Step 131A

For 2007-2009 model years, the temperature sensor is located on the back of the Elbow as installed in Step 87A. Re-connect the temperature sensor connector to the stock wire harness. To connect the sensor connector, first slide the connector fully into the stock connector until the retaining tab “clicks” into place. Then slide the red locking clip to lock it in place.

Step 131B

For 2010-2018 model years, the temperature sensor is located on the EGR crossover tube. Examine the EGR temperature sensor wire harness connector to see what color it is. If the stock connector is grey, (2012-2018 model years) you will be using the Extension Harness with the grey connector (Item 27). If the stock connector is black (2010-2011 model years), you will be using the Extension Harness with the black connector (Item 33).

Step 132

For 2010-2018 model years, connect the appropriate colored Extension Harness connector to the stock EGR temperature sensor connector. To connect the harness connector, first slide the extension connector fully into the stock connector until the retaining tab “clicks” into place. Then slide the red locking clip in the direction shown until it locks into position.

Step 133

For 2010-2018 model years, connect the Extension Harness connector to the EGR temperature sensor on the crossover tube. To connect the harness connector, first slide the connector fully on to the sensor until the retaining tab “clicks” into place. Then slide the red locking clip in the direction shown until it locks into position.

Step 134A

For 2010-2018 model years, loop the extra length of the Temp Sensor Extension Harness as shown by the green arrow. Loop the extra length of the stock EGR Valve harness as shown by the blue arrow. Use (1) Push In Cable (Zip) Tie (Item 29) around both harnesses as shown by the red circle. Leave the Push In Cable Tie loose for now and push in the retainer into the hole in the throttle heat shield.


For 2007-2009 model years, you should not need the Temp Sensor Extension Harness so just use (1) Push In Cable (Zip) Tie (Item 29) around the stock wire harness and insert the push in retainer into the hole in the throttle heat shield before tightening the zip tie on to the stock wire harness.

Step 134B

For 2010-2018 model years, use (2) Cable (Zip) Ties (Item 28) on both sides of the Push In Cable Tie to fasten the Temp Sensor Extension Harness to the stock harness as shown. Tighten the (2) Cable (Zip) Ties and leave the center Push In Cable Tie loose at this time.

Step 134C

For 2010-2018 model years, use (1) Cable (Zip) Tie (Item 28) to neatly fasten the extra length of the stock EGR Valve wire as shown.

Step 134D

For 2010-2018 model years, use (1) Cable (Zip) Tie (Item 28) to fasten the EGR Valve Extension Harness to the Temp Sensor Extension Harness as shown.

Step 134E

For 2010-2018 model years, tighten the Push In Cable (Zip) Tie (Item 29) to fasten the EGR Valve Extension Harness to the throttle heat shield.

Step 135

Use a Flush Cutter to cut and remove the excess cable tie ends.

Tools Required: Flush Cutter

Step 136

The finished wire harness should be nicely arranged and secured as shown.

Step 137

To make clearance for the new #1 Fuel Line (Item 5), cut and extend the slot in the stock foam fuel tube silencer with a Snap-Blade Knife. Extend the slot all the way until it is flush with the interior of the foam silencer as shown.

Tools Required: Snap-Blade Knife

Step 138

Carefully install the foam fuel tube silencer over the fuel injector tubes and gently push down into position.

Step 139

Reposition the wire harness that was draped over the driver side fender in Step 49. Position the wire harness to its original location going underneath the oil dipstick and wrapping around the back side of the cylinder head. Re-attach the stock wire harness retaining clip to the oil dipstick as shown.

Step 140

Connect the wire harness connector to the exhaust pressure sensor located next to the EGR bypass valve. To connect the harness connector, first slide the connector fully on to the sensor until the retaining tab “clicks” into place. Then slide the locking clip in the direction shown until it locks into position.

Step 141

Connect the wire harness connector to the EGR bypass valve located by the passenger side of the cylinder head. To connect the harness connector, first slide the connector fully until the retaining tab “clicks” into place. Then slide the locking clip in the direction shown until it locks into position.

Step 142

Connect the wire harness connector to the crankcase pressure sensor 2 located on the passenger side of the crankcase breather cover. To connect the harness connector, first slide the connector fully onto the sensor until the retaining tab “clicks” into place. Then slide the locking clip in the direction shown until it locks into position.

Step 143

Attach both wire harness retainers to the threaded studs located on the passenger side of the crankcase breather cover.

Step 144

Connect both fuel injector wire harness connectors located on the driver side of the crankcase breather cover. To connect the harness connector, slide the connector fully into the housing until the retaining tab “clicks” into place.

Step 145

Connect the wire harness connector to the crankcase pressure sensor 1 located behind the driver side of the crankcase breather cover. To connect the harness connector, first slide the connector fully onto the sensor until the retaining tab “clicks” into place. Then slide the locking clip in the direction shown until it locks into position.

Step 146

Re-attach 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 into the hose barb. Make sure the CCV oil drain hose next to the Intake Elbow is not being pinched by the Intake Elbow or fuel rail return line.

Tools Required: Panel Popper

Step 147

Using a Flush Cutter, cut and remove the retaining clip on the grid heater cable. Be careful not to damage the wire harness.

Tools Required: Flush Cutter

Step 148

Fasten the Extension Cable (Item 17) to the heater grid cable using the M6 x 16mm long Hex Flange Screw (Item 19) and the M6 Flange Locknut (Item 32). Position the Extension Cable in the position and orientation shown. Torque the fasteners to 88 lb-in.

Tools Required: M10 Socket, M10 Open/Box Combination Wrench, Torque Wrench

Step 149

Slide the Heat Shrink (Item 20) over the exposed metal contact of the Extension Cable and stock heater grid cable, then shrink the Heat Shrink with a Heat Gun. Make sure there is no exposed metal or tears after shrinking the Heat Shrink.

Tools Required: Heat Gun

Step 150

Slide the second Heat Shrink (Item 20) over the first Heat Shrink, then shrink the Heat Shrink with a Heat Gun. Make sure there is no exposed metal or tears after shrinking the Heat Shrink.

Tools Required: Heat Gun

Step 151

Slide the Fabric Heat Shrink (Item 21) and cover the entire extension including the Heat Shrink (Item 20), then shrink the Fabric Heat Shrink with a Heat Gun. Make sure there is no exposed metal or tears after shrinking the Fabric Heat Shrink.

Tools Required: Heat Gun

Step 152

The finished extended grid heater cable assembly should look like the picture shown.

Step 153

Slide the Terminal Insulator (Item 18) over the end of the finished grid heater cable assembly as shown.

Step 154A

If your Intake Air Heater is Type B (See Step 102 for Type B identification). Remove and discard the top nut. Leave the bottom nut and wave spring washer on the threaded stud and proceed to Step 154B. If your Intake Air Heater is Type A (See Step 102 for Type A identification), do nothing and proceed to Step 154B.

Step 154B

Apply some blue thread locker to the top end of the threaded stud on the Intake Air Heater (Item 15).

Step 155

Route the extended grid heater cable to travel down the side of the cylinder head and wrap around back towards the Air Intake Heater as shown. Make sure to arrange the contact terminal (of the Extension Cable, Item 17) so that the “flat side” of the contact terminal will face down towards the Intake Air Heater and the “cable wire side” of the contact terminal will face upwards away from the Intake Air Heater as shown.

Step 156

Place the Extension Cable (Item 17) contact terminal so that the threaded stud of the Intake Air Heater goes through the contact terminal hole. Make sure to place the “flat side” of the terminal facing down towards the Intake Air Heater and the “cable wire side” of the terminal facing upwards as shown. Use an M5 Flanged Locknut (Item 16) on top of the grid heater contact terminal and hand tight at this time. Make sure that the contact terminal is only touching the threaded stud of the Intake Air Heater so that it will not cause any electrical shorts.

Tools Required: 8mm Socket/Wrench

Step 157

Make sure that the extended grid heater cable is positioned so that it can be zip tied up against the oil dipstick. Use (4) Cable (Zip) Ties (Item 28) to securely hold the extended grid heater cable to the oil dipstick and wire harness as shown.

Step 158

Hold the bottom M5 nut with an 8mm open wrench to prevent the threaded stud from rotating and possibly twisting or breaking as you torque down the top M5 Flanged Locknut.Then torque the top M5 Flanged Locknut on the Intake Air Heater threaded stud to 35 lb-in.

Tools Required: 8mm Open Wrench, 8mm Socket, Torque Wrench.

Step 159

Verify again that the contact terminal is only touching the threaded stud of the Intake Air Heater so that it will not cause any electrical shorts. Then slide the Terminal Insulator (Item 18) over the end of the extended cable contact terminal and cover the Intake Air Heater threaded stud as shown.

Step 160

Tighten the Cable (Zip) Ties (Item 28) and use a Flush Cutter to cut and remove the excess cable tie ends. The finished assembly should look clean and secured as shown.

Tools Required: Flush Cutter

Step 161

Follow the grid heater cable around the cylinder head making sure it is not rubbing against the Intake Elbow or any hot or moving engine components.

Step 162

Connect the wire harness connector to the TMAP sensor located on the Intake Elbow (for location reference, see Step 86). To connect the harness connector, slide the connector fully onto the TMAP sensor until the retaining tab “clicks” into place.

Step 163

Connect the wire harness connector to the throttle valve located on the Intake Elbow (for location reference, see Step 25). To connect the harness connector, first slide the connector fully onto the throttle valve until the retaining tab “clicks” into place. Then slide the locking clip to lock the retaining tab.

Step 164

Locate the wire harness bulkhead by the driver side firewall and re-attach the wire harness retainer. For location reference, see Step 27. If the wire harness retainer is worn out and does not hold the harness securely, replace the retainer with a Push In Cable (Zip) Tie (Item 29). 

Step 165

Re-attach the wire harness bulkhead by the driver side firewall and rotate the latch to lock the wire harness bulkhead together.

Step 166

Re-attach the coolant hose bracket bolt (from Step 8) and tighten.

Tools Required: 10mm Socket/Wrench

Step 167

Re-connect the negative battery cable on the driver side battery. Tighten the battery terminal nut.

Tools Required: 8mm Socket/Wrench

Step 168

Re-connect the negative battery cable on the passenger side battery. Tighten the battery terminal nut.

Tools Required: 10mm Socket/Wrench

Step 169

Inspect your installation, make sure the Intake Elbow, all associated stock parts, and all fasteners and hose clamps are properly secured. Make sure that all wire harnesses moved during installation are secure and away from hot or moving engine components. Keep all stock parts in case you ever need to reinstall the stock intake elbow assembly. If you are an installer, give the owner the QR code for the Installation Instructions so that he/she is aware of the Maintenance and Operation procedures given in the beginning of the Instructions. The installation is now complete.