Bully Dog 52100 Dodge 5.9L Cummins 94-02 RFI Owner's manual

Brand: Bully Dog

Model: 52100 Dodge 5.9L Cummins 94-02 RFI

Type: Owner's manual

INSTALLATION MANUAL

Applications RFI Part Number

Dodge 5.9L Cummins

’94-’02

52100

Not legal for sale or use in California on pollution-controlled vehicles.

Table of Contents

TABLE OF CONTENTS

INTRODUCTION ............................................................................................... PG. 2

BILL OF MATERIALS ......................................................................................... PG. 2

REMOVING THE STOCK INTAKE ......................................................................... PG. 3

INSTALLING THE RFI ......................................................................................... PG.4

FILTER MAINTENANCE ...................................................................................... PG.5

WARRANTY & DISCLAIMER .............................................................................. PG. 6

TROUBLESHOOTING:

Technical support is available by calling 866-bullydog

(866-285-5936).

INTRODUCTION

Introduction: The following instruction set covers installation and maintenance of the Rapid Flow

induction system for 1994-2002 Dodge Cummins 5.9L.

Introduction

BILL OF MATERIALS

RFI Housing

Filter

Band clamp

TOOLS NEEDED

Screw Driver

PREFILTER RECOMMENDED

Recommended with this kit but not included is a Bully Dog

prelter which can be purchased through a local Bully Dog

dealer. A prelter blocks large particles and insects from

becoming lodged in the lter ribs. This keeps air ow at a

maximum and makes cleaning much easier.

Stock Removal

REMOVING THE STOCK INTAKE

1. Using a screwdriver, loosen the band clamp that holds the

intake tube onto the stock lter housing. Disconnect the

intake tube from the intake housing.

2. Remove the lid of the stock intake housing by unsnapping

the clips that hold the lid in place. Also remove the stock

lter pannel.

3. Notice the three screws at the bottom of the stock, these

three screws are what secure the intake box to the vehicle.

Unscrew the three screws using your hands, if they are to

tight use pliers to initially loosen. After all of the grommets

are loosened remove the bottom part of the intake from the

vehicle.

4. Remove the rubber grommets from the stock air box, with

the screws still attached to the grommets, they will need to

be installed on the Bully Dog RFI.

Installation

INSTALLING THE RFI

1. Notice the RFI heat sheild has three holes on the bottom.

Install the rubber grommets/screws taken from the stock

intake box onto the RFI heat sheild.

2. Set the RFI lter housing into the engine bay. Line up the

threaded posts on the coming upward from the fender well

to the screw holes on the intake sheild. Secure the intake

sheild by tightening the screws installed on the RFI to the

threaded posts.

3. Connect the intake hose over the RFI Outlet Secure the con-

nection using a at head screwdriver.

4. Place the air lter onto the outlet tube on inside of the in-

take heat sheild. Secure the lter using a at head screw

driver to tighten the provided band clamp around the end

of the lter.

Filter maintenance

FILTER MAINTENANCE:

The intake system should be cleaned at least once every three months; in dusty climates the lter

should be cleaned more often. Cleaning the intake is a two part process, the rst part of the process

involves the physical cleaning of the lter with soap and water and the second part involves oiling the

lter. To properly clean the lter, a Bully Dog cleaning kit should be used. Cleaning kits are available

at any Bully Dog dealer.

PART 1, CLEANING THE FILTER:

1. Remove lter from lter housing. Clean the lter housing if

necessary.

2. Begin the cleaning process by ridding the lter of any dirt by

lightly tapping it. Then brush away any loose particles with a

soft-bristle brush. This step can usually be avoided with the

use of a prelter.

3. Spray cleaner generously over entire lter and let soak for

10 minutes.

4. Thoroughly rinse the lter with regular tap water (avoid

high-pressure hoses). Flush from the inside out or clean side

to the dirty side to prevent dirt from entering the lter.

5. Let the lter air dry before oiling, do not use any method to speed up the drying process. Using

a blow dryer or compressed air can cause the lter to disgure which would then allow particles

to pass through the lter.

PART 2, OILING THE FILTER:

1. Apply a small amount of oil to the soft bristle brush and spread the oil over the lter. Be sure to

apply a small amount of force so not to damage the lter element.

2. Continue applying oil to the lter using a soft bristle brush until the entire lter is covered in an

even amount of oil, just enough to give the lter a solid blue color. Apply enough oil to make the

lter a solid and uniform blue, but do not go beyond that.

3. Allow oil to sit for 20 minutes. Re-oil any dry spots that appear. Do not oil lter excessively. Exces-

sive oiling can cause damage to intake sensors.

PART #: 229000

CLEANING KIT

Prelter

PART #: 229000

CLEANING KIT

AIR FILTER PREFILTER

• Extend Time Between Cleanings

• Hydrophobic Material Repels Water

• Protects Cone Filter from Large Debris

• Maintains Filter Airﬂow Between Cleanings

Bully Dog PreFilter (Part # 225301 for your intake)

The time between scheduled lter maintenance can be extended. Using a Prelter will prevent all

large debris from getting into the ribs of the lter. When using the prelter only ne dust particles

make it through the prelter and onto the exterior of the lter. Thus when using a prelter,

scheduled cleaning easy much easier and lter life is even positively eected.

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.52100-99 v2.1

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

Bully Dog 52100 Dodge 5.9L Cummins 94-02 RFI Owner's manual

Bully Dog 52100 Dodge 5.9L Cummins 94-02 RFI Owner's manual

Bully Dog 52100 Dodge 5.9L Cummins 94-02 RFI Owner's manual

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