• Please read the entire installation manual before proceeding.
• Ensure all components listed on page 10 are present.
• If you are missing any of the components, call our customer support at (909) 947-0015.
• Do not work on the vehicle while the engine is hot.
• Make sure the engine is turned off, the vehicle is in Park and the Parking Brake is set.
2.5, 4, & 5mm Hex Key
6, 10, & 13mm Wrench or Socket
5/16” Nut Driver or Flathead Screwdriver
1/8”, 1/4” Drill Bit
Center Punch or Awl
Heavy Duty Wire Cutter
Utility Knife or Scissor
Straight-edge or Cardboard
#3 Phillips Screwdriver
THREAD LOCKER USE
We have provided a small tube of thread locker in your kit. Whenever you see the symbol above on a step of the instructions, apply 1 small drop of the thread locker to the threads of the screws or bolts. This will keep your hardware from vibrating loose during rough driving. If the hardware ever needs to be removed, do so slowly to avoid having the inserts strip out from the plastic.
Loosen the four (4) hand screws in the recessed cups holding down the cargo bed. Remove cargo bed, and set aside. (It may be helpful to have two people for this step as the cargo bed is large and awkward).
Loosen the hose clamp on the airbox inlet boot with the 6mm socket, and push it down to the airbox.
Remove the intake cover by sliding the cover toward the rear of the vehicle. Set the cover on a sturdy surface that you are willing to destroy. A trash can may suffice. Also, the shipping box for this kit would work.
Push up on the airbox inlet boot, pushing it off of the airbox inlet. Pull down on the top of the air inlet boot, dislodging it; once the boot is free on both ends, compress it together to remove it, slipping past the airbox. The airbox does not need to be removed. See image for the boot removed from the vehicle.
Cut out the included template as shown. As the circle is just for reference, the cut does not need to be perfect, but it does require the circle’s center.
Tape off the area where the hole saw will be cutting the cover.
Line up the template with the sides of the cover, perpendicular to the ground. The side of the cover is slanted, so the side/flap of a box, or some other straight edge, is a helpful tool when aligning the template.
Tape off the template, and use a sharp object to mark the center of the circle, indenting the cover beneath.
Drill a pilot hole with a 1/8” drill bit. The cover is thin and soft, but the hole saw has a tendency to wander without pre-drilling.
Next drill the hole to 1/4”, the arbor bit of the Hole Saw (W) will suffice. Pre-drilling the hole in this way will improve the accuracy of the cut.
Use the Hole Saw to cut through the cover.
Sand or otherwise deburr the rough edges left by the Hole Saw.
Reinstall the intake cover.
Place the #40 Hose Clamps (B) onto the airbox inlet, ensure the hose clamps are fully loosened.
Slide the Tube Shroud (Z) onto the Intake Tube, up to the groove on the tube. Install the Coupler (A) onto the Intake Tube. The assembly should look as shown.
Install the Coupler over the Airbox Inlet and slide the #40 Hose Clamps to their appropriate grooves. Tighten the Hose Clamps when satisfied with the direction the Intake Tube is pointing.
The Tube Shroud is designed to allow the Intake Tube to point in any direction. Select a direction and align the Tube Shroud on the Intake Tube accordingly. The S&B Filters text indicates the front of the Tube Shroud.
Select a location to Install the Particle Separator (E). For a top roll bar mounting use the 1.75 Inch Clamp Straps (I).
For a double inside roll bar installation use the 1.5 Inch Clamp Straps (P).
Wrap a piece of plastic around the roll bar and slide the Clamp Straps onto the bar.
Install the Pivot Body (H) onto the Strap with the supplied Screw (K), Locknut (M), and Washers (J). Do not fully tighten the screws and locknuts.
Install the Adapter (F) on the mounting bosses of the Particle Separator (E) with the supplied Screws (N) and Washers (O). Apply Threadlocker (U) to the screw before installing. Tighten these screws. Repeat this for both sides.
Determine the proper angle to mount the L Bracket (G) to the Adapter based on the desired location for the Particle Separator. When installing the L Bracket, make sure the ribs in the L Bracket are properly seated inside the grooves of the Adapter. Do not attempt to rotate these parts once assembled.
Once you’re satisfied with these configurations apply Threadlocker to the Screw (L) then tighten with the Washer (J). Repeat for the other side of the Particle Separator and make sure the L Bracket on both sides are pointed in the same direction.
Install the L Bracket onto the Pivot Body using Screw and Washer. Apply Threadlocker to the screw before installing. You may have to adjust the position of the Strap and pivot body to get the holes to line up. Do this for both sides.
Once you are satisfied with the position, tighten the Screw, Locknut, and Washer to secure the Strapat the roll cage. Do this for both sides.
Double-check that all screws and locknuts are tight and that they are securely holding the Particle Separator assembly to the roll cage.
Insert one end of the Duct (C) onto the plenum of the Particle Separator, do not tighten. Bring the other end towards the Intake Tube. Note the length needed to create the connection. We recommend adding an extra 3” more to the length of the duct needed.
Pierce the Duct using a utility knife, centered between the two-wire reinforcements. Cut all the way around, keeping the blade centered between the wire reinforcements the entire length of the cut.
Use the heavy-duty wire cutter to cut through the wire and duct. Use the utility knife to cut through any remaining duct not yet cut.
Install the Flex Duct End Cuffs (X) onto each end of the Duct. Place a #56 Hose Clamp (D) at each end of the duct, in the clamp groove of the Flex Duct End Cuff.
Install one end of the duct onto the Intake Tube and the other end onto the Particle Separator. Tighten both #56 Hose Clamps. The product should look as pictured when finished.
Remove the Center Console Cover by turning the thumb screw at the top of the cover and pulling the cover upward.
Locate the Battery.
Remove the Negative Battery Connector with the 10mm Socket/Wrench. Next, remove the Positive Battery Connector with the 10mm Socket/Wrench.
Familiarize yourself with the Wire Harness (T) and each of the connectors, pigtail, fan connector and ring terminals. The Pig Tail Wire is used in conjunction with the Posi-Tap (V) to tap into a switched power source. The Ring Terminals go to the battery and the Fan Connector goes to the Particle Separator.
Locate the wire with the tag “SW. ACC A”. This is the key-on source that will be tapped to supply power to the signal wire of the universal harness. The other two wires require a dash switch to complete their respective circuits.
Place the top of the Posi-Tap over the “SW. ACC A” wire.
Screw the Posi-Tap pieces together..
Cut off the ring terminal and strip the signal wire pigtail on the Wire Harness and insert it into the Posi-Tap.
Connect the Positive Ring Terminal of the Wire Harness to the Positive Battery Connector. Next, connect the Negative Ring Terminal of the Wire Harness to the Negative Battery Connector.
The wires hide nicely if routed to the sides of the battery.
Route the Fan Connector Wire of the Wire Harness through the hole in the back wall.
Feed the Fan Connector Wire up toward the airbox along with the cross member to the desired side for mounting the Particle Separator. Pull the wire up through the rear most vertical roll bar. Connect Fan Connector, turn the key to accessory mode to ensure the fan starts and the wiring is correct.
Tie-down any loose wires using the provided cable ties and flush cut the ties for a professional appearance.
Return to the battery compartment. The extra length of cabling can be secured with cable ties as shown, in front of the battery. The bracket in front of the battery features some holes that can be used to mount the bundle.
Reinstall the Center Console Cover, and the Rear Cargo Bed, ensuring that all hose clamps are tight. Installation is complete.
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