Automotive Manual PDF

Installation Instructions:
1. Disconnect negative battery cable. Then loosen all three factory hose clamps located at the Mass Air Flow (MAF) meter and both factory intake tube.
2. Remove black cover on throttle body by pulling up and sliding towards front of truck. It is held by two grommets. Gently pry the radiator hose bracket from the factory intake tube assembly and remove the tube from the vehicle. A flat head screwdriver may be used.
3. Remove the factory air filter base and lid as an assembly. There are no bolts, just friction mounts, so just pull straight up on the air filter base to remove. Then remove the plate that held the base and lid. There are (5) 10mm bolts to unscrew to remove the plate. After everything is removed it should look like the picture above.
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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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You have just purchased the finest turbo system available for the 6.9 and 7.3 liter diesel engine. The following information will assist you in the installation of your ATS turbo system.

IMPORTANT: It is very important to read all the instructions carefully prior to any installation of your turbo system. Normal mechanical and safety procedures should be followed.
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Step 1
Set parking brake on vehicle and disconnect the negative battery terminal.
Step 2
Remove flexible inlet hose from throttle body and air box by loosening two hose clamps. Disconnect the tube to the valve cover and the inlet air temperature sensor if applicable.
Step 3
Remove plastic cover on the left side of the throttle body. Unhook the throttle cable from the throttle body link-age, disconnect the throttle position sensor and vacuum hose from throttle body.
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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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The Dyna III Electronic Ignition System has been designed for easy installation and does not require the use of special tools. The compact electronic module operates efficiently and was designed to clamp to a frame tube. It can be located anywhere that there is sufficient space, and does not require special considerations as it is completely vibration and water proof. The recommended location is on the left frame tube under the fuel tank. The DYNA III System was designed for use with stock coils. however. it may be used with other coils that have at least THREE OHMS primary resistance.
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This overview section serves only as a step by step reminder for experienced workers. If you are unfamiliar with any procedure you should read the parenthetical reference article or Paul Glaves’Routine R1100 Service Article!
Note to R1100RT and R1100RS Riders: remove the side panels as described in your owners manual “Service and Technical Booklet”except RT: instead of pulling the mirror off as the manual says, you need to hold the back of the mirror (front of bike) with one hand while you hit the front outside corner of the mirror with the palm of your hand thus knocking the mirror off.
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Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition is okay.
VALVE CLEARANCE
NOTE: Adjust valve clearance with engine cold.
NOTE: If valve cover uses grommets below retaining nuts or bolts, keep grommets in order so they are installed in original locations during reassembly.
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The following actions were taken in order of time needed to perform them…
Verified that the plug wire was transferring energy to the #1 plug by removing (from the spark plug, not the distributor) it and holding it close to the engine block. The presence of a spark at regular intervals demonstrated that the wire was acceptable. Also the ignitor and distributor were OK because the other 5 cylinders were firing normally. After changing the #1 spark plug, the symptom remained. This verifies the presence of a spark in the cylinder.
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R1100 Maintenance Steps - Carl Kulow
Note: This overview section serves only as a step by step reminder for experienced workers. If you are unfamiliar with any procedure you should read the parenthetical reference article or Paul Glaves’Routine R1100 Service Article!

Note to R1100RT and R1100RS Riders: remove the side panels as described in your owners manual “Service and Technical Booklet”except RT: instead of pulling the mirror off as the manual says, you need to hold the back of the mirror (front of bike) with one hand while you hit the front outside corner of the mirror with the palm of your hand thus knocking the mirror off.
(more…)

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