K&N GEN II AIR INTAKE INSTALL

By Dan Wilson

Heres a Picture of the entire K@N cold air intake kit.

* I suggest you still use the provided instructions, I think this write up will be helpful though because they give you crappy pictures to go by in the instructions.

* Disconnect the negative battery cable from the battery

1. Disconnect the the crankcase vent line from the air cleaner assembly. I put a rag over the throttle body to keep any dirt from getting inside it.
   
2. Remove the factory air filter housing from the throttle body, remove the factory gasket, don’t worry about saving it because the kit gives you a new gasket.
3. Disconnect the air inlet hose from the fender and remove the entire assembly, I suggest saving all factory air intake components just in case.
4. There is a Z shaped bracket for one of the heat shields, you’ll find an existing hole in the radiator core support, its not easy to see but if you look hard you’ll find it,this is where you mount the Z bracket.
5. On 94-97 models theres an existing hole in the fender by the old air intake duct and this is where you mount the long L shaped bracket. On 98-99 models you have to remove the bolt that holds the leak detection pump bracket to the inner fender and use that hole and bolt to mount the L shaped bracket to the fender.
   
6. Refer to the instructions as to which bolts to put in the heat shields. You want to do this before you mount the heat shields to the brackets because these bolts are necessary to mount the two shields together.
7. There are two pieces of the heat shield, one piece will mount to the Z shaped bracket and one will mount to the long L shaped bracket. The two pieces are different so refer to the picture to see which one mounts where. Do not tighten all the way because to get the air filter through the shield you have to be able to move it around slightly to get the best fit.
8. Once the heat shields are mounted you can mount one shield to the other, one shield will strattle the inner fender, this may vibrate sometimes against the inner fender when going down the road but wont hurt anything except it will be annoying.
   
9. Theres a saddle bracket that goes underneath the new intake tube, right now you want to assemble it and mount it to the heat shield under the open area for the intake tube.
10. Install the provided screw into the threaded hole in the throttle body, this screw will be a pain in the neck later on, you’ll see.
11. Now install the new gasket over the throttle body.
12. You’ll have to cut the factory crankcase vent hose for the best fit for it to go to the new vent tube, cut little by little until you get the desired length. This is difficult because it mounts in back of the vent tube and because of the firewall it is tough to attach it to the back, very limited space.
13. You can attach the crankcase vent hose to the vent tube now and attempt to put the vent tube over the gasket but with all the moving around you have to do I suggest you do it once the vent tube is secure on the throttle body.
14. Now install the vent tube over the screw in the throttle body and onto the new gasket, This part is very difficult because of the cab forward design of the engine. Getting the vent tube over the screw and seating it on there correctly is very difficult so be patient. To make sure the vent tube is seated on the bolt, install the nut extension through the vent tube hole and see if it is threading on the bolt (don’t be surprised if it doesn’t thread on the first few times. You might have to move the vent tube around to get it directly on the screw. MAKE SURE THE VENT TUBE SITS ON THE GASKET PROPERLY.
    
15. Now secure the intake tube to the saddle bracket assembly with a hose clamp.
16. Once you get the intake tube where you want it you can tighten the bolts on the heat shield and on the brackets.
17. Install the side location trim seal onto the slot on the heat shield, secure the a/c line to the heat shield with the zip tie.
18. Install the filter to the intake tube using the hose clamp. Make sure the hose clamp is on the filter good because thats all that holds the filter onto the intake tube. A couple of times from vibration my hose clamp loosened and my air filter came off so make sure it is tight.
19. Use the trim seal along the top of both heat shields, you’ll have to cut it to the desired lengths.