2003-2007 Ford Powerstroke 6.0L Airaid Intake System Installation
1. Disconnect both negative battery cables. Unlatch all four factory clips on the factory airbox.
2. Remove factory air filter by separating the inlet and outlet sections of the assembly.
3. The filter is held in place by two rubber grommets on the bottom.(Note: make sure factory grommets remain in lower air box support.)
4. Disconnect electronic filter restriction gauge connector and remove the restriction gauge, and rubber grommet.(Note: retain these parts for later use.) Remove air filter inlet tube and hose assembly. USE CAUTION when removing these elements, as it is a tight fit. Be careful not to tear the factory insulation around the radiator support.
5. STOP AND LOOK! If you have a temperature sensor like this, proceed to step # 8. The early production 2005 F-250 and F-350 6.0 diesel trucks either came with a temperature sensor, or they came with a Mass Air Flow sensor. These pictures will help you determine which sensor you have. Whichever sensor you have, this Airaid Intake System will fit.
6. IF YOU HAVE A MASS AIR FLOW SENSOR LIKE THIS, A.) Disconnect the electrical connector, and remove the two screws using the supplied T-20 security bit, and remove the sensor. (Retain the sensor for later use.) B.) Using a 5/16” socket loosen the hose clamp on the end of the intake tube.
7. Remove complete factory air filter tube assembly. (Note: do not remove flexible turbo inlet hose from turbo housing.)
8. A.) If you have the temperature sensor shown in step #5, install the supplied grommet as shown above. B.) Install the factory air temperature sensor as shown, and then the factory grommet and filter restriction gauge. Skip to step #10.
9. A.) If you have the sensor shown in step # 6, install the gasket and sensor using 2 (black) 8/32”x 5/8” screws. B.) Install the factory grommet and filter restriction gauge.
10. Slide the Airaid filter tube into factory flexible turbo inlet hose. (Note: Do not tighten hose clamp until assembly is complete.) Reconnect the sensor to the factory plug. (Either the temperature sensor or the mass air sensor, which ever you have.)
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