DINAN D760-0063 Cold Air Intake System Instruction Manual

DINAN D760-0063 Cold Air Intake System Instruction Manual

Thank you for being selective enough to choose a Dinan Performance Intake System. The Dinan Engineering Team has spent many hours developing this product to assure that you will receive increased performance, durability and an aesthetic design that you as a customer will be able to enjoy for many years. Ease of installation and maintenance is important to us and has been highly considered throughout the design process.

Prior to performing the installation, familiarize yourself with these instructions as it should help you with the process. If you feel that you do not have the required skills or tools, please arrange for a qualified repair facility to perform the installation.

If you have any difficulties during the installation, or if these instructions are not clear to you, please call Dinan’s Technical Support Staff at 800-341-5480.

Again, thank you for choosing Dinan. Enjoy.

PARTS LIST

REMOVAL OF STOCK SYSTEM

1. STEP 1:
   Remove front and rear brace by removing bolts and nuts as shown in yellow circles.
   Remove engine cover, pulling upward- Green (1).
   Remove electronics cover, pulling upward- Green (2).
   

2. STEP 2:
   Remove push pins of left airbox intake tube (yellow).
   Disconnect connector shown in red to allow for install clearance.
   

3. STEP 3:
   Loosen clamps where intake tubes mate with airbox lids, both sides.
   

4. STEP 4:
   Remove the airbox, both sides, pulling upward. Ensure that the rubber grommets holding the lower boxes to the chassis are still positioned in the vehicle.
   

5. STEP 5:
   Pull out retaining clamp, as shown, and remove rear turbo inlet tube.
   Ensure to protect the turbos from debris entering the inlet.
   

6. STEP 6:
   Pull out retaining clamp, as shown, and remove front turbo inlet tube.
   Ensure to protect the turbos from debris entering the inlet.
   Removal of stock system is now complete.
   

DINAN INSTALLATION

1. STEP 1:
   Tighten the plenum bracket to the plenum as shown using (2x) M4x10 countersunk screws.
   

2. STEP 2:
   Slide coupler boots, D762-0285 and D762-0286 over ends of plenum.
   Boot shall sit flush against face and wrap around edge of plenum, on both sides.
   

3. STEP 3:
   Using pliers and a cloth, bend the tabs as shown into the vertical position.
   This will help with clearance during the installation of the Dinan system.
   

4. STEP 3.1:
   Ensure all tabs are pulled up. Some models may have an extra tab as shown in the image.
   Orientation of tabs is shown in image. This should be done on both passenger and driver side of panel.
   

5. STEP 4:
   Slide hose clamps onto tubes. Small hose clamp on long tube. Medium hose clamp on short tube. Pre-install both rubber hoses onto the stock turbo inlet tubes. Do not tighten clamps as alignment to plenum is needed.
   The longer rubber hose shall attach to the rear turbo. The shorter rubber hose shall attach to the front turbo.
   The inside lip on the hose shall snap over the front lip of the turbo inlet tubes. Ensure seated all around.
   

6. STEP 5:
   Hoses shall be in shown orientation. Small rotation may be needed.
   

7. STEP 6:
   Place a rag/cloth over the metal panel as shown.
   

8. STEP 7:
   Place plenum in engine compartment to ensure proper alignment of hoses. Align mounting tab with mounting hole as shown (red).
   Plenum outlet ports shall slide into hoses. May need to press down on plenum slightly.
   This shall be the final position of the rubber inlet hoses.
   

9. STEP 8:
   Remove plenum and tighten clamps at turbo inlet for both the inlet tubes as installed in STEP 4 and 5.
   

10. STEP 9:
    On a clothed surface, slide airbox lids onto plenum as shown.
    

11. STEP 10:
    Slide large clamps onto air filter collar.
    Seat air filters onto plenum. Filter pleat seam shall be visible as shown.
    Once oriented properly, tighten clamp to a snug fit.
    

12. STEP 11:
    Position each lower box as shown.
    

13. STEP 12:
    Using rubber washers and self-threading screws provided, start thread into lower box.
    Do not tighten until all screws are engaged in lower box.
    

14. STEP 14:
    Tighten all screws. Do not over tighten. Screws shall only compress rubber washers slightly.
    

15. STEP 15:
    Position the two remaining medium clamps onto the inlet hoses in orientation as shown.
    Tighten clamps as needed to maintain position only. Do not compress hose at this time.
    

16. STEP 16:
    Carefully lower the entire airbox and plenum assembly into the vehicle.
    Make sure the cloth is still on the front of vehicle to protect during this step.
    

17. STEP 17:
    Ensure both lower boxes slide into proper position with stock inlet tract as showN.
    Ensure plenum seats fully into the Dinan intake hoses.
    Press both airboxes into the stock rubber grommets from STEP 4.
    Hose clamps will be tightened after STEP 18.
    

18. STEP 18:
    Re-install connector as shown.
    Re-install braces and torque to:
    Bolt: 28 Nm (20 ft-lbs)
    Nuts: 56 NM (41 ft-lbs)
    This fully seats the plenum.
    FULLY TIGHTEN HOSE CLAMPS AS SHOWN IN STEP 17.
    
    

19. STEP 19:
    You have now completed the installation.
    Ensure all hoses are tightened and bolts are torqued.
    The extra DINAN badge is for your placement discretion. If choosing to place on the intake, the adjacent photo shows a suggested location. ENJOY and remember to remove all tools and extra parts from the engine compartment prior to closing of the hood.
    

Support

Dinan Engineering
4800 US Hwy 280 West
Opelika, AL 36801
Phone: 800.341.5480

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