RFI COLD AIR INTAKE INSTALLATION MANUAL Applications GM Silverado and Sierra 6.6L Duramax LLY 2004.5-2006 RFI Part Number 53106 Not legal for sale or use in California on pollution-controlled vehicles.
RFI COLD AIR INTAKE Introduction This manual provides step-by-step installation instructions for the Bully Dog Rapid Flow Induction (RFI) Cold Air Intake for 2004.5-2006 GM 6.6L Duramax LLY vehicles. Installation requires a few basic tools and takes about 20 minutes. Table of Contents Parts.................................................................... 2-4 Installation........................................................... 5-11 Maintenance.......................................................
RFI COLD AIR INTAKE Parts Description RFI Lid The easy-to-remove lid replaces the stock lid and allows for hassle-free filter maintenance. When the lid is installed, the latch mounts should line up with the latches on the base. This will ensure that the lid creates a good seal with the enclosure base and that the latches close securely.
RFI COLD AIR INTAKE RFI MAF Tube The air intake tube comes with a precisely manufactured mount for the stock mass airflow (MAF) sensor. The mount has inset screw mounts that are designed to work with the black oxide screws provided by Bully Dog. The tube is also designed with a snap-fit feature that will secure it tightly to the RFI base.
RFI COLD AIR INTAKE Silicone Couplers The high-quality 3-ply couplers are durable, flexible and strong. Worm Drive Band Clamps Adjustable clamps connect and hold all tubing in place. T20 Security Torx® Bit Bully Dog includes a Torx® bit for convenience. Black Oxide Phillips Screws Bully Dog provides two 3/8” black oxide screws and nylon washers to secure the MAF sensor to the RFI MAF tube. Nylon Washers These nylon washers protect the mass airflow sensor and prevent it from being bent.
RFI COLD AIR INTAKE Installation Installation is very simple and can be separated into three parts: Removing the Stock Intake, Preparing the Bully Dog RFI Intake and Installing the Bully Dog RFI Intake. The complete installation of the RFI Cold Air Intake system should take about 20 minutes. The assembly diagram shows how the parts of the intake fit together in sequence. Removing the Stock Intake Band Clamp (3) Mass Air Flow Sensor (2) Stock Intake Tube (3) Band Clamp (3) Stock Intake Box (4) 1.
RFI COLD AIR INTAKE 2. Unplug the mass airflow (MAF) sensor. 3. Remove the stock intake tube. • Loosen the band clamps at each end of the tube. (Use a flat-head screwdriver.) • Do not completely disconnect the clamps; just loosen them enough to remove the tube. • Lift the tube out of the engine bay and set it aside. 4. Remove the stock intake box. • Gently pull upward; the box is held in place by rubber grommets and should easily pop out.
RFI COLD AIR INTAKE 5. Remove the mounting plate. • Remove all five machine screws. (Use a 10 mm socket). • Set aside three of the machine screws. (You will need them to install the RFI base.) 6. Remove the silver sticker from the side of the engine bay.
RFI COLD AIR INTAKE Preparing the RFI Intake 1. Snap the RFI MAF Tube into the RFI Base. 2. Remove the MAF sensor from the stock intake tube. (Use the T20 Torx® bit.) 3. Attach the MAF sensor to the RFI MAF Tube. • Use the MAF Sensor Gasket. • Use one nylon washer (slid beneath the MAF sensor) and one black oxide Phillips screw on each side. IMPORTANT: Do not overtighten the screws, as this could damage the MAF sensor.
RFI COLD AIR INTAKE 4. Prepare the Stage 2 RFI Tube. • Connect the hump coupler to the MAF side. • Connect the straight coupler to the turbo side. • Attach the band clamps. • Do not tighten the band clamps; leave them loose so you can adjust the couplers into the correct position. 5” Band Clamp 5” Band Clamp Silicone Hump Coupler 4” Band Clamp 4” Band Clamp Silicone Coupler Installing the RFI Intake 1. Install the RFI base assembly. a.
RFI COLD AIR INTAKE 2. Install the prepared Stage 2 RFI tube. a. Connect the silicone couplers to the turbo inlet tube and the RFI MAF tube. b. Leave the band clamps loose until all of the connections are properly aligned. c. When the tube and couplers are in the correct position, tighten the band clamps. (Use a flat-head screwdriver.) 3. Install the air filter. a. Connect it to the end of the RFI MAF tube that is inside the RFI base. b. Tighten the band clamp. (Use a flat-head screwdriver.
RFI COLD AIR INTAKE 4. Install the RFI lid. a. Make sure the lid is properly aligned. b. Snap the latches over the mounts on the lid. 5. Reconnect the MAF sensor plug and the battery. Start the vehicle, listen for leaks and check all connections.
RFI COLD AIR INTAKE Filter Maintenance The intake system should be cleaned with the Bully Dog RFI Cleaning Kit at least once every three months; in dusty climates, the filter should be cleaned more often. Cleaning the intake is a two part process: cleaning and oiling the filter. (1) Cleaning the Filter 1. Remove the filter from the RFI enclosure. Clean the enclosure if necessary. PART # 229000 2. Remove surface dirt (this step can be avoided if a Bully Dog RFI Prefilter has been installed).
RFI COLD AIR INTAKE 2. Continue applying the oil to the filter until the entire filter is covered in an even amount of oil. Apply enough oil to make the filter a solid and uniform blue, but do not go beyond that. 3. Allow the oiled filter to sit 20 minutes. Re-oil any dry spots that appear. Do not oil the filter excessively. Excessive oiling can cause damage to intake sensors.
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RFI COLD AIR INTAKE Doc.53106-99 v1.1 Check out more of our ADRENALIN PUMPING products! Triple Dog GT Pre Filter Cleaning Kits Clothing GT Diesel is not legal for sale or use in California on pollution-controlled vehicles. Free Technical Support at: 1-940-783-9915 See More at: bullydog.
