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How to Install K&N Series 77 High Flow Performance Cold Air Intake on your Dodge Ram
Tools Required
- ratchet
- extension
- 10mm socket
- 13mm socket
- flat blade screw driver
- ¾’ wrench
Shop Parts in this Guide
PARTS LIST:
NOTE: FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS AND NOT USING THE PROVIDED HARDWARE MAY DAMAGE THE INTAKE TUBE, THROTTLE BODY AND ENGINE.
TO START:
1. Turn off the ignition and disconnect the negative battery cable.
NOTE: Disconnecting the negative battery cable erases pre-programmed electronic memories. Write down all memory settings before disconnecting the negative battery cable. Some radios will require an anti-theft code to be entered after the battery is reconnected. The anti-theft code is typically supplied with your owner’s manual. In the event your vehicles anti-theft code cannot be recovered, contact an authorized dealership to obtain your vehicles anti-theft code.
2. Loosen the hose securing the intake tube to the intake plenum.
3. Disconnect the crank case vent hose from the valve cover fitting and then lift up and remove the air filter housing and intake tube to remove it from the vehicle.
4. Disconnect the inlet air temperature sensor electrical connection and remove the bolt shown that secures the intake plenum. Lift up and remove the intake plenum from the vehicle.
NOTE: K&N Engineering, Inc., recommends that customers do not discard factory air intake.
5. Install the provided coupling hose (08496) onto the throttle body and secure with the provided hose clamp.
6. Install the heat shield side wall onto the heat shield and secure with the provided hardware.
7. Install the filter adapter into the heat shield and secure with the provided hardware.
8. Install the provided edge trim onto the heat shield as shown.
NOTE: Some trimming of the edge trim will be necessary.
9. Install the provided heat shield mounting bracket (083103-1) onto the heat shield using the provided hardware.
NOTE: be sure to install the provided spacer between the heat shield and bracket.
10. Install the provided heat shield mounting bracket (083127) onto the heat shield using the provided hardware.
11. Install the provided hump coupler (08699) onto the filter adapter and secure with the provided hose clamp.
12. Remove the core support bolt shown.
NOTE: This bolt will be reused in a later step.
13. Remove the air filter housing mounting bracket bolt shown.
NOTE: This bolt will be reused in a later step.
14. Install the heat shield into the vehicle and secure with the factory bolts removed in the previous steps.
15. Install the provided grommet into the K&N® intake tube as shown.
16. Install the 90º NPT fitting into the K&N® intake tube as shown.
NOTE: Plastic NPT fittings are easy to cross thread. Install the vent fitting “hand” tight, then turn it two complete turns with a wrench.
17. Remove the inlet air temperature sensor from the factory air filter housing.
NOTE: Be careful removing the inlet air temperature sensor as it is very fragile.
18. Remove the sealing O-ring from the sensor and then install the inlet air temperature sensor into the grommet installed into the intake tube.
NOTE: Be careful installing the inlet air temperature sensor as it is very fragile.
19. Install the K&N® intake tube into the coupler at the heat shield and then into the coupler at the throttle body. Adjust the tube for best fit and then secure with the provided hose clamp.
20. Reconnect the inlet air temperature sensor electrical connection.
21. Install the provided crank case vent hose onto the valve cover port and then connect the open end to the fitting installed into the K&N® intake tube.
22. Install the K&N® air filter onto the adapter and secure with the provided hose clamp. NOTE: Drycharger® air filter wrap; part # RF-1020DK is available to purchase separately. To learn more about Drycharger® filter wraps or look up color availability please visit http://www.knfilters.com®.
23. Reconnect the vehicle’s negative battery cable. Double check to make sure everything is tight and properly positioned before starting the vehicle.
24. It will be necessary for all K&N® high flow intake systems to be checked periodically for realignment, clearance and tightening of all connections. Failure to follow the above instructions or proper maintenance may void warranty.
ROAD TESTING:
1. Start the engine with the transmission in neutral or park, and the parking brake engaged. Listen for air leaks or odd noises. For air leaks secure hoses and connections. For odd noises, find cause and repair before proceeding. This kit will function identically to the factory system except for being louder and much more responsive.
2. Test drive the vehicle. Listen for odd noises or rattles and fix as necessary.
3. If road test is fine, you can now enjoy the added power and performance from your kit.
4. K&N Engineering, Inc., requires cleaning the intake system’s air filter element every 100,000 miles. When used in dusty or off-road environments, our filters will require cleaning more often. We recommend that you visually inspect your filter once every 25,000 miles to determine if the screen is still visible. When the screen is no longer visible some place on the filter element, it is time to clean it. To clean and re-oil, purchase our filter Recharger® service kit, part number 99-5050 or 99-5000 and follow the easy instructions.
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