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How to Install Rugged Ridge Polished Aluminum Air Intake on your 1997-2006 Wrangler
Shop Parts in this Guide
Contents:
1. Intake Tube (1)
2. Heat Shield (1)
3. Weather Stripping
4. Air Filter (1)
5. Throttle Body Coupling (1)
6. Large Hose Clamps (3)
7. Breather Hose (1)
8. Small Hose Clamps (2)
9. Throttle Body Spacer (1)
10. Throttle Body Gaskets (2)
11. M6 Throttle Body Bolts (4)
12. Throttle Linkage Spacers (3)
13. M6 Throttle Linkage Bolts (3)
14. M8 Mounting Bolt (1)
15. M8 Flat Washers (2)
16. M8 Nut (1)
17. Rubber Isolator Mount (1)
18. M6 Washers (2)
19. M6 Nuts (2)
20. Zip Tie (1)
21. Grommet
1. Remove original Air Filter, Air Box, Intake Tube, Intake Temperature Sensor, and Breather Tube.
2. Install Rubber Isolator Mount to the vehicle in the rear-most hole that was utilized by the stock air box. Fasten to vehicle using M6 Flat Washer and M6 Nut from below.
3. Install Weather Stripping on Heat Shield, and install Heat Shield into vehicle. The front of the Heat Shield is secured with one of the factory radiator mounting bolts. The bottom of the Heat Shield is secured with the M8 Bolt, Washers, and Nut through a hole left by the removal of the factory air box. The rear of the Heat Shield is secured to the Spreaded Bar with a Zip Tie.
4. Remove 4 bolts that fasten the throttle body to the intake manifold. Lift throttle body and remove gasket. Install Throttle Body Spacer in between throttle body and intake manifold, using supplied longer bolts. Install supplied gaskets between intake manifold and throttle body spacer, and between throttle body spacer and throttle body.
5. Remove 2 bolts that hold the throttle cable bracket to the intake manifold. Use supplied M6 Throttle Linkage Bolts and Throttle Linkage Spacers to space throttle cable bracket up.
6. Remove the Intake Temperature Sensor from the original Intake Pipe. Pry the tab up, then twist to remove.
7. Remove O-Ring from Intake Temperature Sensor. Install the Sensor into the Grommet as shown, and then install both into the Intake Tube.
8. Install Throttle Body Coupling onto the Throttle Body using a Large Hose Clamp. Install Intake Tube into vehicle, routing it into the area seperated by the Heat Shield. Use a Large Hose Clamp to attach the Intake Tube to the Throttle Body Coupling. Hook up Intake Temperature Sensor plug. Fasten the open end of the Intake Tube to the Rubber Isolator Mount using an M6 Flat Washer and M6 Nut.
9. Using supplied Breather Hose and Small Hose Clamps, hook the breather up to the open port on the Intake Tube.
10. Install the Air Filter onto the Intake Tube using a Large Hose Clamp to secure it. Note: This filter is polyester synthetic and never needs to be oiled. It can de cleaned with warm water and mild detergent dish soap.
11. Congratulations on the purchase and installation of another quality Rugged Ridge product.
