Bully Dog 51204 Ford 6.2L F250-F350 2011+ Owner's manual

Brand: Bully Dog

Model: 51204 Ford 6.2L F250-F350 2011+

Type: Owner's manual

RFI COLD AIR INTAKE

INSTALLATION MANUAL

Applications RFI Part Number

Ford 6.2L F250-F350 2011+ 51204-99

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 the

2011+ Ford 6.2L F250 and F350 trucks. Installation requires a

few basic tools and takes about 20 minutes.

Table of Contents

Parts ..................................................................... 1-4

Installation ............................................................ 5-14

Maintenance ........................................................ 15-16

Parts Included

RFI Lid .................................................................. (51200-1)

MAF RFI Tube ...................................................... (51201-3)

Stage 2 RFI Tube ................................................. (51204-3)

Air Filter with Band Clamp ................................... (224900)

9.5 mm Silicone Hose .......................................... (51202-7)

16 mm Silicone Hose ........................................... (51201-6)

Silicone Coupler – 57 mm .................................... (51200-5)

Silicone Coupler – 76 mm .................................... (51200-6)

#6 Hose Clamp (2) ............................................... (10800-2)

#8 Hose Clamp (2) ............................................... (10800-4)

4” Worm Drive Band Clamp (4) ............................ (51105-7)

T20 Security Torx® Bit ......................................... (229120)

Black Oxide Phillips Screw (2) ..............................(54100-94)

Nylon Washer (2) .................................................. (51201-94)

Zip Tie (2) ............................................................. (1-NYTIE8)

Tools Needed

• Flat-head screwdriver

• Phillips screwdriver

• 10 mm socket

• Bit Driver

RFI COLD AIR INTAKE

Parts Description

RFI Lid

The easy-to-remove lid

replaces the stock lid and

allows for hassle-free lter

maintenance. When the

lid is installed, the OEM

latches secure the lid to the

box.

RFI MAF Tube

The RFI MAF tube comes with a precisely manufactured

mount for the mass airow

(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-t feature that will

secure it tightly to the RFI

lid.

Stage 2 RFI Tube

Designed to t in your

engine bay, the stage 2

RFI tube improves air ow

into the turbo through the

smoothest curves possible

to prevent any loss of

power and provide sleek

style under the hood.

RFI COLD AIR INTAKE

Air Filter with Band Clamp

The Rapid Flow Induction

(RFI) Cold Air Intake system

includes an ISO 5011

certied eight-layer oil lter.

The air lter is housed within

the intake enclosure and

secured onto the end of the

air intake tube using the

included lter clamp and a

at-head screwdriver.

Silicone Hose and Couplers

The high quality 3-ply hose and couplers are durable, exible

and strong.

Hose and Band

Clamps

Adjustable clamps connect

and hold all tubing in place.

RFI COLD AIR INTAKE

T20 Security Torx® Bit

The mass air ow sensor is

attached to the stock intake

tube using tamper resistant

pin-in-Torx® screws. Bully

Dog includes a Torx® bit for

convenience. If the bit is lost it can be purchased at any auto

parts store.

Black Oxide

Phillips Screws

Bully Dog provides screws

to secure the mass airow

sensor to the MAF tube.

Nylon Washers

The nylon washers protect

the mass airow sensor and

prevent it from being bent

when it is attached to the

MAF tube.

Zip Ties

Use the zip ties to secure

parts within the engine bay.

RFI COLD AIR INTAKE

Installation

The RFI installation

procedure can be

separated into three

parts: Removing

the Stock Intake,

Preparing the RFI

Intake and Installing

the RFI Intake. The

diagram on the

right shows how the parts of the RFI Cold Air Intake t together

in sequence.

Removing the Stock Intake

1. IMPORTANT: Before beginning installation, disconnect your

battery at the negative terminal.

Failure to disconnect the battery

could result in personal injury and/or

damage to your vehicle.

OEM Intake Lid

Resonator Box

CCV Tube (8)

Brake Vacuum Tube (8)

Band Clamp (3)

Mass Air Flow Sensor (2)

Coolant Overow Hose (5)

RFI COLD AIR INTAKE

2. Unplug the mass airow sensor.

• Pull the red tab on the bottom of the plug to unlock it.

• Disconnect the sensor clip by pulling gently.

3. Loosen the band clamp on the resonator box.

4. Release the latches on the stock intake lid.

5. Unclip coolant overow hose.

RFI COLD AIR INTAKE

6. Remove the stock intake lid and tube. (You can take these

out together as one piece.)

7. Remove the stock air lter.

8. Disconnect the CCV and brake vacuum tubes from the

resonator box.

• Unclip the CCV tube.

• Pull the rubber brake vacuum tube o the box.

RFI COLD AIR INTAKE

9. Detach the coolant overow tube from the resonator box.

• Pull the tube away from the clips that secure it to the left

side of the resonator box.

• Disconnect the two white barb connectors on the back of

the resonator box.

• Tuck the tube back into a safe place while you complete

the installation.

10. Remove the two bolts that secure the resonator box in the

engine bay. (Use a 10 mm socket.)

RFI COLD AIR INTAKE

11. Remove resonator box from the engine bay.

12. Loosen the band clamp connecting the resonator box

coupler to the throttle body using a athead screwdriver

and remove the coupler.

13. Use the enclosed zip ties to secure the vacuum tube to the

ECM cable harness.

• Don’t pinch the vacuum tube.

• Clip the excess length o the zip tie.

RFI COLD AIR INTAKE

Preparing the RFI Intake

1. Snap the RFI MAF tube into the RFI lid.

2. Install the air lter by connecting it to the RFI MAF tube.

• Connect it to the end of the tube that has been snapped

into the RFI lid.

• Use a at-head screwdriver to tighten the band clamp.

3. Remove the MAF sensor from the stock intake tube. (Use

the included Torx® bit.)

RFI COLD AIR INTAKE

4. Attach the MAF sensor to the RFI MAF tube.

• Use the nylon washers and black oxide screws provided

by Bully Dog.

• Use one washer on each side.

• IMPORTANT: Do not overtighten the screws, as this

could damage the MAF sensor.

5. Connect the silicone couplers to the Stage 2 RFI tube.

• The long coupler connects with the RFI MAF tube.

• The short coupler connects to the throttle body.

• Put the band clamps on, but leave them loose.

6. Put the hose clamps on the silicon hoses, but leave them

loose.

90˚ Silicone Hose

Straight Silicone Hose

RFI COLD AIR INTAKE

Installing the RFI Intake

1. Install the RFI lnstall the RFI lid/tube assembly.

• Line up the latch mounts on the lid with the latches on

the stock intake enclosure.

• Close the latch

2. Install the Stage 2 RFI tube.

• Connect the silicone couplers to the RFI MAF tube and

the throttle body.

• Connect the silicone hoses to the barbs on the Stage 2

tube as shown in the photo/diagram.

90˚ Silicone Hose

Straight Silicone Hose

RFI COLD AIR INTAKE

3. Swap the CCV tube and the brake vacuum tube with the

included silicone hoses.

• Disconnect the stock tubes only when you are ready to

install the silicone hoses. (This is easier than locating the

connection at a later time.)

4. Tighten all of the band clamps after all of the parts

are in place and connected correctly. (Use a at-head

screwdriver.)

5. Reconnect the MAF sensor plug and the battery.

• Make sure that the red tab on the sensor plug locks into

place.

RFI COLD AIR INTAKE

6. Start the vehicle, listen for leaks and check all connections.

Go for a ride and enjoy.

Be sure to check out the information about lter maintenance

and the protective prelter described in the next section.

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 lter should be cleaned more often. Cleaning the intake is a

two part process: cleaning and oiling the lter.

(1) Cleaning the Filter

1. Remove the lter from the RFI enclosure.

Clean the enclosure if necessary.

2. Remove surface dirt (this step can be

avoided if a Bully Dog RFI Prelter has

been installed).

• Lightly tap the lter.

• Use a soft-bristle brush to remove any

loose particles.

3. Spray the cleaner generously over the

lter and let it soak for 10 minutes.

4. Thoroughly rinse the lter.

• Use regular tap water.

• Avoid high-pressure hoses.

• Prevent dirt from entering the lter by rinsing from inside

out or from the clean side to the dirty side.

5. Let the lter air dry.

• Do not use any method to speed up the drying process.

• Using a blow dryer or compressed air can disgure the

lter and allow particles to pass through.

(2) Oiling the Filter

1. Apply a small amount of oil to the soft-bristle brush and

gently spread the oil over the lter. Be sure to apply only

a small amount of force so the lter is not damaged.

Part# 229000

RFI COLD AIR INTAKE

2. Continue applying the oil to the lter until the entire lter

is covered in an even amount of oil. Apply enough oil to

make the lter a solid and uniform blue, but do not go

beyond that.

3. Allow the oiled lter to sit 20 minutes. Re-oil any dry spots

that appear. Do not oil the lter excessively. Excessive

oiling can cause damage to intake sensors.

Prelter

The Bully Dog RFI Prelter is a semi-water-

repellent barrier that will keep bugs and

debris out while lengthening the

time between lter cleanings

and reducing the amount of

time you spend cleaning the

lter.

RFI COLD AIR INTAKE

NOTES

RFI COLD AIR INTAKE

NOTES

RFI COLD AIR INTAKE

Free Technical Support at: 1-940-783-9915

See More at: bullydog.com

Clothing

Triple Dog GT Pre Filter

Check out more of our ADRENALIN PUMPING products!

Cleaning Kits

Doc.# 51204-99 v1.3

GT Diesel is not legal for sale or use in California on pollution-controlled vehicles.

Bully Dog 51204 Ford 6.2L F250-F350 2011+ Owner's manual

Bully Dog 51204 Ford 6.2L F250-F350 2011+ Owner's manual

Bully Dog 51204 Ford 6.2L F250-F350 2011+ Owner's manual

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