Automotive Manual PDF

1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable.
3. Disconnect the mass air sensor electrical connection.
2. Remove the 8mm bolt that retains then engine cover onto the engine then remove the cover from vehicle.
4. Loosen the hose clamp at the throttle body.
5. Loosen the hose clamp at the mass air sensor.
6. Detach the intake tube from the throttle body and mass air sensor then remove the intake assembly.
NOTE: K&N recommends that customers do not discard factory air intake.
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1. Park the vehicle on flat level ground. Set the emergency brake and properly block the tires.
2. Raise the front of the vehicle and support the frame rails using jack stands. Remove the front tires.
3. Remove the bushing and washer from the upper portion of the factory shock. Place the new upper frame bracket over the factory bracket. (See Photo #1). Now reinstall the upper bushing and washer onto the factory shock.
4. Push the bracket up flush against the frame. The outside mounting hole on the top plate will now line up with the factory hole in the upper mount. Drill out the factory hole using a 13/32” drill bit. Install the 3/8 x 1 fine thread bolt with washers and locknut at this location. (See Photo #2).
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STOCK EXHAUST SYSTEM REMOVAL
1. Remove frame cover.
2. Remove right side footpeg assembly held in place by two bolts (Figure 1).
3. Remove exhaust port nuts.
4. Remove bolts securing rear muffler to exhaust system mounting bracket.
5. Remove complete exhaust system. Begin by lifting muffler out of mounting bracket locating hole (assistance may be required).
6. Check condition of stock exhaust gaskets. Replace if damaged or worn.
7. Remove two bolts attaching stock exhaust mounting bracket to frame.
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PREPARATION
1. Remove the EVAP hose, brake booster hose, PCV hose, vacuum hose, water bypass hoses, throttle cable, fuel lines, fuel injector connectors, IAC valve connector, TP sensor connector, MAP sensor connector, and EVAP canister purge valve connector from your current intake manifold and throttle body setup.
2. Remove the throttle body.
3. Remove the intake manifold brackets, intake manifold, and intake manifold gasket.
If adapting an Accord Euro R or 06 Civic Si intake manifold onto an 02-06 RSX/ITR or 02-05 Civic Si/CTR style head, continue to follow the remaining “PREPARATION” steps, otherwise skip to “INSTALLATION”
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When installing this exhaust system make sure to use proper safety precautions. Use jack stands when working under the vehicle, set parking brake, block tires and use safety glasses and gloves. Allow exhaust to cool before attempting installation. Severe injury or burns could occur if safety measures are not taken.

SUGGESTED TOOLS: 1/2″, 9/16″, 15mm wrenches & sockets, WD-40, hacksaw, and jack stands
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Getting Started
a) Make sure vehicle is parked on a level surface. Set parking brake.
b) Disconnect negative battery terminal from the battery.
c) If engine has run within the past two hours, let it cool down.

Removal of the stock intake system.
a) Before removing any of the O.E. components, label each individual part so that no components become mixed up during the installation process.
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Installation Instructions
1. Figure 2 shows a cable bracket which holds a brake line to the inside of the frame rail. Loosen this bracket from the top of the frame and move the brake line down about 1/2” so that it is not interfering with hitch cross members.
2. From underneath the passenger’s side of vehicle remove or cut out the section of the heat shield that is located between the frame rails and the bed of the vehicle.
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TO START:
1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable.
2. Depress the locking clip on the mass air sensor electrical connection, and then separate the mass air sensor electrical connection.
3. Loosen the hose clamp that retains the stock intake tube to the resonator, and then remove the tube from the resonator as shown.
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If your vehicle is equipped with vibration dampers between the turns of the coil, it is necessary that these be removed before installing the air springs.Their function will be replaced by the air spring. Some mid-size GM vehicles have a solid cup located on the lower spring seat which will not allow the air line to exit the coil. It is necessary to removed this cup before installing the air spring.
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Installation Instruction:
1. Carefully examine the location of fuel lines, brake lines and electrical wires before installation. Be certain you will not damage fuel lines, brake lines or electrical wires when positioning hitch components, drilling holes, tightening fasteners, and lifting and lowering the truck bed.
2. Read installation manual and installation drawing completely. Understand all components and parts before installation.
3. Hitch ball location: Two wheel Drive Short & Long Bed 49” 46” Four wheel Drive Short & Long Bed 49” 46” Ball location in front of axle 6-1/2” 3-1/2”
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