Flowmaster 615183D Installation guide

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ϲϭϱϭϴϯ

ZĞǀ06ͬ12ͬ19

WĂŐĞϭŽĨϳ

2. Usethepartsdrawingandlist(frontpage)to

verifyyourkit’scontents.

Intheunlikelyeventthatanypartsaremissing,

contactFLOWMASTERTechnicalSupportfor

replacements.

TosimplifyassemblyandavoidcrossͲthreading

fasteners,identifyandseparatethe¼Ͳ20screws

(item10)(usedwithnuts(16)andheatshield

cover(5)),andtheM6screws(13)(usedwithfilter

adapter(3)andbarbedpins(14)).

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Rev06/12/19

REVIEWTHEINSTRUCTIONSAND

VERIFYTHEKITCONTENTS:

NOTES

•Wehighlyrecommendthatyouretainallfactory

airintakesystemparts.

•Refertoyourvehiclemanufacturer’s

recommendationsregardingremovaloffactory

components.

•Disconnectingthenegativebatterycableerases

preͲprogrammedelectronicmemories.Write

downallmemorysettingsbeforedisconnecting

thenegativebatterycable.Someradioswill

requireanantiͲtheftcodetobeenteredafterthe

batteryisreconnected.TheantiͲtheftcodeis

typicallysuppliedwithyourowner’smanual.In

theeventyourvehicle’santiͲtheftcodecannotbe

recovered,contactanauthorizeddealershipto

obtainyourvehicle’santiͲtheftcode.

REMOVETHEFACTORYAIRINTAKESYSTEM:

1. Takeamomenttoreadandunderstandthese

instructionsbeforeinstallingyourFlowmaster

performanceairintakekit.

3. Turnoffthevehicle’signitionanddisconnectthe

negativebatterycable.Failuretodisconnectthe

batterymaycausetheCHECKENGINElightto

illuminateaftertheairintakekitisinstalled.

4. Removethe3intakemountbolts.

5. DisconnectthePCVlinefromtheairinletduct.

6. Disconnecttheairtemperaturesensorplugby

depressingthelockingtab,thenpullingitstraight

offthesensor.

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Rev 06/12/19

7. Separatethe3wireloomclampsfromthe

resonator.

8. Loosenthescrewclampconnectingtheinletair

ducttothethrottlebody,thenseparatetheduct

fromthethrottlebody.

9. Pulltheairboxupsharplytoreleaseitfromits

mountgrommets,thenremovetheassembled

airboxandductsfromthevehicle.

LIFT

TAB

1/4

TURN

CCW

10. Removetheairtempsensorbyliftingthelocking

tabandturningthesensoraquarterͲturncounterͲ

clockwise,thenpullingitstraightoutoftheduct.

ThenremovetheoͲringfromthesensor.CAUTION:

Thesensorisdelicate! Handleitwithcare,and

storeitinasafelocationuntilreinstallation.

12.Atthebracketjustforwardofthebattery,remove

theinboardscrew.

11.Ifeitheroftherubbermountgrommetscameout

ofthevehiclewiththeairbox,removethemfrom

theairboxandinstallthemintheirholesinthe

vehicleframe.

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Rev 06/12/19

ASSEMBLEANDINSTALLYOURFLOWMASTER

PERFORMANCEAIRINTAKESYSTEM:

13.Attachgasket(25)totheheatshield(4),in2

sectionsasshown.Firmlypressthegasketonto

theedge,andcutittolengthusingmetalͲ

cuttingshears.

START

HERE

CUT&

RESTART

HERE

END

HERE

14. Attachgaskettotheheatshieldcover(5).

15.Assembletheairfilteradapter(3)totheheat

shieldusingM6screws(13),lockwashers(8)and

flatwashers(7).

16.Attachthe2brackets(15)totheheatshieldas

shown,using¼Ͳ20screws(10)(againsttheheat

shield),andflatwashers(12),lockwashers(11),

andnuts(16)(againstthebrackets).

17.Fastenabarbedpin(14)toeachbracket,usingan

M6screw(13),lockwasher(8)andflatwasher(7).

18.Inserttherubbergrommet(22)intotheintake

tube(21).Moisteningthegrommetwithsoapy

waterwilleaseinsertion.

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Rev 06/12/19

ORIENTTABTOWARD

FILTEREND

SLIGHTGAPBETWEEN

BOSSANDGROMMET

19.Carefullypushtheairtempsensorintothe

grommet,orientingthetabtowardthetube’s

filterend.MoisteningthegrommetI.D.withsoapy

waterwilleaseinsertion.NOTE:Thesensorboss

doesnotsitflushagainstthegrommet;therewill

beaslightgap.

20.Apply2wrapsofnylonthreadtapetothethreads

ofthequickconnectfitting(20),andinstallitin

theintaketube.

21. Slipa#56screwclamp(19)ontothesmallendof

thereducingcoupler(18),andinstallthecoupleron

thefilterendoftheintaketube.Thenslipthe#64

screwclamp(17)ontotheotherendofthecoupler.

Donottightentheclampsatthistime.

22.Sliptheother#56screwclamp(19)ontothelarge

endoftheelbowcoupler(23),andinstallthe

coupleronthedischargeendoftheintaketube.

Thenslipthe#52screwclamp(24)ontotheother

endofthecoupler.Donottightentheclampsat

thistime.

23.Installtheheatshieldbypressingthe2mount

pinsintotheirrubbergrommets.

24.Securethecorneroftheheatshieldtothevehicle

frameusingthelongM6screw(9),lockwasher

(8),flatwasher(7)andspacer(6).

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Rev 06/12/19

25.PlacethepreͲfilterwrap(28)andthe#104screw

clamp(2)ontheairfilter(1).Theninstallthefilter

onthefilteradapter,andtightentheclamp.

26.Installtheassembledintaketubeinthevehicle.

27.Pushthereducingcouplerfullyupagainstthe

heatshield,thentightentheheatshieldclamp.

PUSHFULLY

AGAINST

HEATSHIELD

PUSHFULLY

AGAINST

THROTTLEBODY

28.Pushtheelbowcouplerupagainstthethrottle

bodystops,thentightenthethrottlebodyclamp.

29.Centertheintaketubebetweenthecouplers,

thentightenthe2remainingclamps.

CENTERTUBE

BETWEEN

COUPLERS

30.ConnectthePCVlinetothequickconnectfitting

andcheckforsecurity.

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Rev 06/12/19

31.Connecttheairtempsensorextensionlead(26)

tothevehicle’stempsensorplug.Thenroutethe

leadunderthecoupler,connecttheotherendto

theairtempsensor,andcheckforsecure

connectionsatbothends.

33.Attachtheheadshieldcovertotheheatshield

using¼Ͳ20screws(10),lockwashers(11),andflat

washers(12).

Congratulations,theinstallationofyour

FLOWMASTERperformanceairintakekitisnow

complete!

32.Use1or2cableties(27)(asnecessary)tosecure

thetempsensorleadtonearbywiringorplumbing.

IMPORTANT:RETAINTHESEINSTRUCTIONS

FORFUTUREREFERENCE

www.flowmastermufflers.com

TechnicalSupport(866)464Ͳ6553

Page1of1DFC

Rev06/12/19

3. Blowthrough thefilter,fromtheinsideout.Keep

thenozzlemoving;donotholditstationaryover

oneplaceonthefilter.

Replaceyourfilterevery15Ͳ30,000miles—more

oftenunderdustyconditions,lessoftenundernormal

highwayconditions.

PREͲFILTERWRAP

IfthepreͲfilterwrapisused,washitasneededwith

warmwateranddishsoap,rinsewithclearwater,

andpatdrywithatowel.

DRYSYNTHETICAIRFILTERS

NEVERWASHYOURDRYAIRFILTER! However,ifyou

driveindustyconditions,periodicallyblowingthe

filteroffwithlowͲpressure(20Ͳ30PSI)compressedair

canextenditsservicelife.

Inspectyourfilteraboutevery6,000miles(or,every

otheroilchange).Whenyouseeabuildupofdust

betweenthepleats:

2. Blowofftheoutside ofthefilter.Blowacrossthe

filtersurface(atabouta45° angle),notthrough

thefiltermaterial.Holdtheairnozzleabout6

inchesawayfromthefiltersurface,alwayskeepit

moving,andpointtheairjetinto—notacross—

thepleats.

CLEANINGYOURFLOWMASTERDRYSYNTHETICAIR

FILTERandPREͲFILTERWRAP

1. Tapthefilterseveraltimesonahard,flatsurface.

Tapitfirmlyenoughtodislodgeanyloose

particlesfromthepleats,butnotsohardasto

damageit.

Flowmaster 615183D Installation guide

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