Automotive Manual PDF

To Install
1. Attach the CTI Line with the swivel nut to the air valve.
2. Remove the ―” X 20 Nyloc Nut from the Valve
3. Put the air valve in the valve hole and hold in place.
4. Place Stainless Washer on Inside of Wheel under the Nyloc Nut.
5. Hand tighten the ―” X 20 Nyloc Nut onto the air valve.
6. Put the 9/16” open- end wrench on the swivel nut.
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Installation instructions for the 2003-2007 Express and Savana Vans
Use your 10-mm socket and ratchet to remove two (2) washer nuts from the inside of the small cubby hole under the radio and airbag switch. Set the washers aside. Remove two (2) 10-mm screws from the bezel below the steering column. Set the screws aside. Pull the bezel toward you releasing six (6) clips. On the pas- sengers side, remove two (2) 10-mm screws on the lower bezel below the glove box. Set the screws aside. Pull toward you to release two (2) clips and a pin that is connected to the larger radio bezel.
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All left / right descriptions are from the point of view of the rider when seated on the bike in the riding position.
Note: the condenser upgrade cable supplied will have a black cover to make it inconspicuous enough for a concours show bike. The example shown has a red cover to highlight the correct location and routing.
1. Place the bike on the center stand.
2. Remove the left side cover.
3. Loosen the rear engine mounting bolt. This is a long bolt that passes through both rear engine hangers. If mounted correctly, the nut, washer and lock washer should be on the right side of the bike. Yours may be reversed.
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If your truck does not have a locking tailgate (like provided on many full size Fords, Toyotas and Nissans), you will need to purchase an aftermarket tailgate lock (i.e., Pop’ N Lock, Bully Tailgate Lock, etc.,) to be able to lock the tailgate shut and to secure your truck bed. These lock sets basically replace your existing tailgate handle and convert it into the equivalent of a factory installed locking tailgate. Changing these tailgate lock handles is the equivalent of changing a “door knob” in that you simply loosen the 2 bolts on the inside of the tailgate, remove your non-locking tailgate handle, and replace with one that locks. These install really easily without any drilling and you can buy these at any truck accessories store. Once the cover is closed (and latched), you just simply lock the cover, then lock up your tailgate handle and you now have a really secure trunk!
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Remove of the interior door panel
Steps:
#1 Use flat head screwdriver to remove the plastic panel along side the window. A 6-mm -socket head screw is now visible to remove.
#2 Use flat head screwdriver to remove speaker grille, (4) 6-mm socket head screw are now visible to remove speaker. You must remove the (4) white nut bosses by pushing from the backside to pop them out.
#3 Use a flat head screwdriver to remove the window control switch panel. Inside the door panel to the left is located 10-mm socket head bolts. Use 10-mm -socket w/ ratchet and 3” long extension to remove.
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This is the process used to install the Turbo Wheel without having to remove the Turbo from your
Engine. It should take a maximum of 5 hours.

Procedure:
• Start by removing the Intake hose
o Remove all of the Intake tubes, exposing the turbo inlet.
o Remove the 2 bolts from the CCV intake mount.
o Move the CCV mount, exposing the 2 Philips screws. Remove the CCV filter from the valve cover. (watch for the O rings)
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Dodge Charger Figure Grille Installation
Figure 1. Examples of low-profile Philips screwdrivers. 1) Ratchet (¼” drive) with ¼” socket and Philips bit. 2) Offset Philips screwdriver.
1.1) Remove radiator covers. Begin by popping the hood of your vehicle. There are two plastic protective shields which cover the radiator area. These are held in place by small clips which will let go easily by pulling on the pieces. Fig. 2 shows these covers and illustrates their removal.
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This bulletin contains service manual correction information for the VZR1800. Please change the valve spring specifications in your dealership service manual based upon the information provided below. Insert a copy of each of the attached pages with clutch washer information into your dealership service manual at the appropriate page.
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