Install Instructions for 83-1002/83-1003

Remove the Engine Oil Cap. No tools required.

Use a 10mm socket to remove the engine cover bolt. With the bolt removed, pull upwards and towards the front of the vehicle to remove the engine cover from the vehicle. Reinstall the engine oil cap once the cover is removed to ensure nothing falls into the engine.

Skip this step and proceed to the hot side section (Step 6) if you purchased only 83-1003. Use a flat head screwdriver or 7mm nut driver to remove the upper hose clamp on the cold side pipe. 

Reach underneath the cold side pipe to loosen the second clamp at the engine side with a flat head screwdriver or 7mm nut driver.

Remove the OEM cold side pipe from the truck.

Remove the OEM Clamp with 7mm nut driver or flat head from the intercooler side of the hot side pipe.

Use a 10mm socket to remove the three bolts holding the engine cover bracket in place. The third bolt is underneath the sensor and visible once the sensor is unbolted and moved aside. The sensor is bolted in with 2 x 10mm bolts. Once unbolted, flip it forwards and rest it on the intercooler.

Remove the engine cover bracket from the truck.

Use a pick to pry upwards on the retaining clip and allow the collar to disconnect from the turbo. 

Fully remove the Hot Side Pipe & Resonator from the truck.  

Place two clamps over the ends of the cold side pipe and prepare for installation into the truck. Index the clamp on the engine side to the bolt is facing towards the driver side wheel well. That way you can access the nut from underneath the intake tube. Index the clamp on the intercooler side so the bolt faces the front of the truck and is lower than the engine cover once installed.

Use an 11mm and tighten both t-bolt clamps. Torque with a calibrated torque wrench to 76 inch lbs. This is extremely important step, an improperly torqued clamp may result in the intercooler pipe blowing off under high boost.  

Install the included S&B snap ring onto the billet collar. Face the S&B logo on the collar up and center the ring on the collar then slide into palce.

Lubricate the o-ring with any type of oil. Then place into the o-ring groove in the billet collar.

Install the collar onto the turbocharger with the S&B Logo facing upwards. Push the collar on until you see the retaining ring seat into the groove. It is extremely important to ensure the retaining ring is fully seated in the groove.

Next, place two clamps on the hot side hose. Index the clamp at the intercooler side so the nut faces the hood on the driver side of the hose. The clamp at the turbo side should face the front of the truck and be on top of the hose. Install the hose in the truck by sliding onto the collar and intercooler.

Loosely set the engine cover bracket back into place to ensure your clamps do not interfere with the engine cover bracket before tightening.

Remove the engine cover to give you more space to tighten the clamps now that you know the position. Use an 11mm and tighten both t-bolt clamps. Torque with a calibrated torque wrench to 76 inch lbs. This is extremely important step, an improperly torqued clamp may result in the intercooler pipe blowing off under high boost.  

Reinstall the engine cover bracket. First, reinstall the 3 10mm nuts/studs that hold the bracket down, then tighten down the 2 10mm bolts that hold the sensor to the bracket. 

Test drive the truck with heavy throttle to ensure your intercooler pipe connections are secure under high boost. Bring your 11mm socket and ratchet with you. Stop driving immediately if you hear a loud noise and experience a loss of power as a connection has come loose. Continued driving with a loose intercooler pipe will destroy the DPF filter. After successful test drive, remove the oil cap and reinstall the engine cover by sliding over the tabs in the rear and then reinstalling the one 10mm bolt that secures the engine cover to the engine. Reinstall the oil cap. The installation is complete