INSTALLATION Manual Rapid Flow Induction Vehicle Application Part Number ‘03,’04,’06,’07 Ford 6.0L Power Stroke #51100 ‘05 Ford 6.
RAPID FLOW INDUCTION TROUBLESHOOTING: If you have questions during the installation of this product, please visit www.bullydog.com/Product_Updates.php. The latest version of these instructions can be found at the same location. Please review the Troubleshooting section on page before calling technical support to cover most common issues. Technical support is available by calling 866-bullydog (866-285-5936). TABLE OF CONTENTS Introduction.....................................................................
RAPID FLOW INDUCTION Introduction Introduction: The following instruction set covers installation and maintenance of the Rapid Flow induction system for 2003-2007 6.0L Ford Power Strokes. Notice that the installation process for the 2005 model year 6.0L has installation differences from the rest of the model years. Prefilter recommended Recommended with this kit but not included is a Bully Dog prefilter which can be purchased through a local Bully Dog dealer.
RAPID FLOW INDUCTION Removing the Stock intake 1. Disconnect the coolant overfill hose, this will make the removal of the stock intake easier. 2. Disconnect the Mass Air Flow sensor: • (‘03, ‘04, ‘06, ‘07) Using a bit driver and the torques bit included unscrew the torques screws that hold the mass air flow sensor onto the air intake exit tube. Once the screws are out pull the mass air flow sensor out of the tube, disconnect it from the harness holder and move it aside while completing the installation.
RAPID FLOW INDUCTION 3. Locate the Air Filter Restriction Gauge on the back of the stock intake housing. Remove the Air Filter Restriction Gauge from the stock intake by simply pulling back on the gauge, it is held in by a rubber grommet and will pull out easily. Once out disconnect it from its communication harness and set it aside. 4. Loosen the band clamp that connects the intake exit hose to the turbo inlet hose and disconnect the tubes. 5.
RAPID FLOW INDUCTION Installing the RFI Pre-Installation Procedure On 2005 models remove the rubber grommet that holds the Mass Air Flow sensor in place from the stock intake housing. Install the rubber grommet into the RFI in the predrilled hole on the intake outlet tube. 1. Notice the two holes at the bottom of the intake seat inside the engine bay. When setting the RFI into place, the rods on the bottom of the RFI will need to set into the two holes. 2.
RAPID FLOW INDUCTION 3. Connect the RFI tube up to the stock turbo inlet hose. Use the stock band clamp to secure the connection; this will require the use of a flat head screw driver. 4. Installing the Mass Air Flow sensor: • (‘03, ’04, ‘06, ‘07): Set the MAF (mass air flow) sensor onto the RFI air outlet tube in the same manner that it was installed on the stock intake tube. Secure the MAF sensor to the RFI using the stock toques screws.
RAPID FLOW INDUCTION 5. Remove the lid from the RFI by pulling upward on the black snaps on top of the lid. Remove the lid the same way whenever performing maintenance on the filter. 6. With the lid off install the filter onto the intake outlet tube and secure it using the band clamp that is included with the filter. If also installing a prefilter put the prefilter over the air filter before installing the air filter. Once the filter is secure the lid can be placed back over the intake.
RAPID FLOW INDUCTION Filter maintenance: The intake system should be cleaned at least every three months; in dusty climates the filter should be cleaned more often. Cleaning the intake is a two part process, the first part of the process involves the physical cleaning of the filter with soap and water and the second part involves oiling the filter. To properly clean the filter a Bully Dog cleaning kit should be used. Cleaning kits are available at any Bully Dog dealer.
RAPID FLOW INDUCTION
RAPID FLOW INDUCTION warranty & disclaimer REMEMBER, THIS IS A PERFORMANCE PRODUCT, USE AT YOUR OWN RISK. This product is not intended to be used to break the law. Do not use this product until you have carefully read the following agreement. This agreement sets forth the terms and conditions for the use of this product. The installation of this product indicates that the buyer has read and understands this agreement and accepts the terms and conditions.
Bully Dog Technologies, LLC is a team built on integrity that is dedicated to leading the vehicle performance industry with an uncompromising code of ethics demonstrated in the soundness of its employees, excellent customer service and superior products. UNLEASH THE POWER WITH BULLY DOG PERFORMANCE PRODUCTS Downloaders Intake Systems Custom OutLook Pod Exhaust Systems See More at: bullydog.com Doc.# BD50012 Version 1.0.0 For a full listing of Diagnostic Trouble Codes go to: www.bullydog.com/DTC.
