Volant PERFORMANCE 15954-D-6-1 Closed Box Air Intake Instruction Manual

IMPORTANT!
WARRANTY AND INSTALLATION
INSTRUCTIONS

15954-D-6-1 Closed Box Air Intake

Please Forward All Information to End Consumer

Be sure to review the enclosed instructions prior to beginning the installation process. If you have any questions about the enclosed parts or instructions, or if you encounter a problem during installation:
CALL TECHNICAL SUPPORT: 440.891.0999 or 800.486.0999

TO ACTIVATE YOUR WARRANTY, GO TO:volant.com/warranty

This warranty does not extend to damaged or defect in the finish of a product or to any product, that in the opinion of Volant Performance, has been misused, damaged by accident or negligence, altered, or modified in any way, faulty installation, or installed contrary to Volant installation instructions, or repaired by an unauthorized service facility.
Full warranty available on Volant.com

NEVER work on a hot engine bay. Allow time for the vehicle to cool.
Always wear eye protection when working on a vehicle.

Color instructions are available at Volant.com. Search by kit number
Please take time to read and understand these installation instructions.
Volant recommends that the installation of this system be performed by a qualified service center or professional installer who has the necessary equipment, tools, and experienced personnel. However, if you decide to perform this installation yourself, the use of an additional person may be required.
WARNING : Never work on a hot engine bay. Allow time for the vehicle to cool. Always wear eye protection when working on a vehicle.

Recommended Tools & Supplies

• 7mm Socket & Ratchet or Wrench
• 8mm Socket & Ratchet or Wrench
• 10mm Socket & Ratchet or Wrench
• Extension for Ratchet
• T20 Torx Driver
• Phillips Screwdriver

INSTALL DIFFICULTY

Please confirm that all parts are present according to the bill of materials before beginning the installation.

Bill of Materials

Hardware Kit:  15953H-1 (5.3L engine) or 15954H-1 (6.2L engine)
H1. Quick Connect Fitting (652188) Qty 1| H2. Thread to Barb Fitting (652189) Qty 1
H3. MAF Sensor Screws (59051214) Qty 2| H4. Lid Washer (59025122) Qty 5
H5. Lid Screw (5900) Qty 5| H6. MAF Sensor Gasket (5619754) Qty 1
H7. Box Opening Seal (56010) Qty 19in| H8. Ø4.0in Hose (531097) Qty 3.0in (6.2L only)
H9. Ø4in to Ø3.5in Reducer (53310) Qty 1 (5.3L only)| H10. Vent Hose (53005) Qty 18in
H11. Hose Clamp #64 (52064) Qty 1 (5.3L Only)| H12. Hose Clamp #56 (52056) Qty 1 (5.3L) or 2 (6.2L)
H13. Vinyl Pack for Lid (652057) (Not Shown)

If something is missing, call Volant Tech Support at 440.891.099 or Toll Free: 1.800.486.0999

Before starting any work on the vehicle, locate the vehicle’s battery and disconnect the negative battery terminal.
This should reset the stock mass air flow data and help prevent CEL errors.

Removal Instructions

Factory Air Intake

1. Locate the vehicle’s battery and using a 10mm Socket & Ratchet or Wrench, disconnect the negative battery terminal.
   Next, disconnect the Mass Air Flow (MAF) Sensor from the Wire Harness by pulling the red clip up and then squeeze the sides of the Wire Conncetor to release it. Leave the MAF Sensor installed for now. It will be removed in Removal Step 8.

2. Using a 7mm Socket & Ratchet or Wrench, loosen the Hose Clamp connecting the Factory Air Duct to the Factory Air Box. This will not be reused.

3. Using a 7mm Socket & Ratchet or Wrench, loosen the Hose Clamp connecting the Factory Air Duct to the Throttle Body. This will not be reused.

4. Locate the Factory Breather Qick Connect Fitting on the Valve Cover. Squeeze the grey clips and pull the Stock Hose free. This will not be reused.

5. Pull the Factory Bellows on the Factory Air Duct off the Factory Air Box.

6. Rotate the Factory Air Duct until it is vertical.
   Then, lift the Factory Air Box up from the bracket located on the vehicle’s engine and remove the Factory Air Duct. This will not be reused.

7. Using an 8mm Socket & Ratchet with an Extension or Wrench, remove the 3 bolts holding the Factory Air Box Lid from the Factory Base, and store them in a safe location. These will be reused in Installation Step 8.

8.  Remove the Factory Air Box Top and Filter.
   These will not be reused.
   The Factory Air Box Base will be reused.
   The 3 screw locations are shown in the circles for reference.

9. Using a T20 Torx Driver, remove the Factory MAF Screws. Carefully remove the MAF Sensor and store it in a safe location. It will be reused in Installation Step 12. The screws will not be reused.

This concludes the removal of the factory intake.

Install Instructions

While it is removed, now is a convenient time to clean the MAF Sensor. There are many resources online or at your local auto parts store about how and what to use to properly clean a MAF Sensor. Ensure the MAF Sensor is dry before reinstalling it
into the Volant Air Intake.

1. Using a Phillips screwdriver, remove the 5 screws and rubber washers securing the Volant Lid. Place the Volant Lid and hardware in a safe location. They will be reinstalled in Step 16.

2. Locate the Volant Air Intake Box Top and the Box Opening Seal. Starting at the Arrow, press the Seal around the opening.
   Excess length of the Seal can be trimmed using a knife or snips. Take care when cutting the Seal as to not cut yourself or damage the Air Intake Box.

3. Locate the Volant Intake Duct and insert it into the Volant Intake Box Top and Seal. Orient the parts as shown.

4. Locate the Thread to Barb Fitting from the Hardware Kit (H2 in exploded view) and carefully thread it into the Volant Air Duct. The Thread to Barb Fitting should be tightened until it is tight and flush to the mating surface on the Air Intake Duct.

5. Locate the Volant Air Filter (PowerCore shown).
   Insert the Filter into the Air Intake Box and then slide the open end onto the Air Intake Duct.
   Rotate the Filter or Clamp so the bolt on the Filter Clamp is accessible and use an 8mm Socket & Ratchet or Wrench to secure the Filter Clamp.

6. Locate either the Ø4in to Ø3.5in Reducer (5.3L) (shown) or Ø4in Hose (6.2L). If installing on a 5.3L engine, slide the smaller Hose Clamp from the Hardware Kit on the smaller side first (shown).
   Place the other clamp over the other side. The hose clamps should be loose at this time.

7. Lift the assembled Volant Air Intake Duct and Box Top into the Vehicle’s engine bay. Align the 3 tabs on the Air Box Top to the Slots in the Factory Air Box Base and slide them into position.  

8. Locate the 3 Screws from Removal Step 7.
   Using an 8mm Socket & Ratchet with an Extension or Wrench, snug the 3 bolts holding the Factory Air Box Lid from the Factory Base.

9. Insert the Volant Air Duct into either the Ø4in to Ø3.5in Reducer (5.3L) (shown) or Ø4in Hose (6.2L), depending on application.
   To get everything aligned, the Volant Air Duct and Filter may need rotated or pushed into the Volant Air Box Top. Once everything is aligned, use an 8mm Socket & Ratchet or Wrench, snug the 2 Hose Clamps on the Reducer or Hose to secure the Air Duct to the Throttle Body.

10. Locate the Hose and Quick Connect Fitting. Press the fitting into one end of the hoses, as shown on the left.
    Next, insert the Quick Connector onto the Valve Cover Port.

11. Route the hose to the fitting in the Air Intake Duct, as shown.

12. Locate the MAF Sensor removed in from Removal Step 8. Remove the Factory MAF Gasket. This will not be reused.

13. Locate the MAF Sensor Gasket and install it onto the MAF Sensor. Next, slide the MAF Sensor and Gasket into the opening in the front of the Air Intake Duct. The Flat Side goes down and the screws will only align one way. Then locate MAF Screws from the Hardware Kit and use a Phillips Screwdriver to secure the MAF Sensor to the Air Intake Duct.

14. Once the MAF Sensor is secured, reconnect the Wire Harness and push the Red Locking tab.  

15. Locate the included Vinyl Pack and Volant Intake Lid.
    The vinyl pack allows customization of the lid with a choice of Clear, Red, White, or Blue for the Volant logo on the lid. Apply the vinyl to the inside of the lid.

16. Locate the 5 screws and rubber washers from Install Step 1. Using a Phillips screwdriver, install the Volant Lid.
    Finally, use a 10mm Socket & Ratchet or Wrench to reconnect and tighten the negative battery terminal.

This concludes the installation of your Volant Air Intake

Check that this air intake complies with your Federal, State and Local laws.
We recommend saving your stock system.

Before Road Testing

1. Start engine, leaving the transmission in park and/or securing the parking brake.
2. Make sure to look and listen for any unusual noises. Repair problems if needed.
3. Once completed it will be necessary to check periodically, after a few heat cycles, for realignment and tightening of all connections.

MAXFLOW 5 Care and Cleaning

The MAXFLOW 5 Filter needs to be periodically checked for dirt build-up. Volant recommends cleaning the MAXFLOW 5 Filter at least two times a year or if you experience a sudden decrease in mileage or engine performance. A two- stage filter recharger kit with cleaner and oil is required. The Volant Filter Cleaner/Degreaser and Oil is available at Volant.com.
Quick Cleaning:

1. Remove the MAXFLOW 5 Filter from the Volant Air Intake. Next, gently tap the MAXFLOW 5 Filter on a hard surface to loosen any dirt build-up and then lightly brush off any loosened dirt.
2. Using Volant Filter Oil (or similar), spray a thin coating to each pleat of the filter. Allow the oil to soak in for a minimum of 20 minutes. Some pleats may need touched-up with more oil, allow the Volant Filter Oil to soak for another 20 minutes before reinstalling the MAXFLOW 5 Filter into the Volant Air Intake.

Deep Cleaning:

1. Remove the MAXFLOW 5 Filter from the Volant Air Intake. Next, gently tap the MAXFLOW 5 Filter on a hard surface to loosen any dirt build-up and then lightly brush off any loosened dirt.
2. Spray the MAXFLOW 5 Filter with Volant Filter Cleaner/Degreaser (or similar) and allow it to soak in for about 10 minutes. Avoid petroleum-based cleaners because they may destroy the sealing edges.
3. Rinse the MAXFLOW 5 Filter with water from the inside to outside to wash away the dirt. Never use high pressure nozzles or compressed air. This may tear and/or distort the filter media and require immediate replacement.
4. Allow the MAXFLOW 5 Filter to completely dry. Never apply heat or compressed air to dry the filter. Never reinstall a wet or damp filter. The MAXFLOW 5 Filter must be completely dry before applying oil.
5. Using Volant Filter Oil (or similar), spray a thin coating to each pleat of the filter. Allow the oil to soak in for a minimum of 20 minutes. Some pleats may need touched-up with more oil, allow the Volant Filter Oil to soak for another 20 minutes before reinstalling the MAXFLOW 5 Filter into the Volant Air Intake.

DryTech 3D Filter Care and Cleaning

Depending on driving and environmental conditions, the DryTech 3D Filter may require cleaning. It is recommended to clean the DryTech 3D Filter at least two times a year. Also, if you experience a sudden decrease in mileage or engine performance, the filter may need to be cleaned or possibly replaced.
Quick Cleaning:

1. Remove the DryTech 3D Filter from the Volant Air Intake and gently tap it on a hard surface to remove any loose dirt.
2. Vacuum the loosen debris from the DryTech 3D Filter.
3. Reinstall the DryTech 3D Filter into the Volant Air Intake.

Deep Cleaning:

1. Remove the DryTech 3D Filter from the Volant Air Intake and gently tap it on a hard surface to remove any loose dirt.
2. Vacuum the loosen debris from the DryTech 3D Filter.
3. Liberally spray the DryTech 3D Filter with Volant Filter Cleaner/Degreaser (or similar) and allow it to soak in for about 10 minutes. Avoid petroleum-based cleaners because they may destroy the sealing edges.
4.  Rinse the DryTech 3D Filter with water from the inside to out to wash away the dirt. Never use high pressure nozzles or compressed air! They will tear and distort the filter media, which will require immediate replacement.
5. Allow the DryTech 3D Filter to completely air dry. Never apply heat or compressed air to dry the filter. Never reinstall a wet or damp filter.

DO NOT OIL!
Oiling your DryTech 3D Filter will ruin it and require immediate replacement.

PowerCore Filter Care and Cleaning

One of the great benefits of the PowerCore Filter is that it doesn’t need to be cleaned. Depending on driving and environmental conditions, the PowerCore Filter will eventually become weighed down with dirt after approximately 100,000 miles or 4 years. To extend the life, periodically remove the PowerCore Filter from the Volant Air Intake and gently tap on a hard surface with the air inlet side down and outlet side (to the Air Duct) up. This will shake loose the dirt trapped in the flow channels within the PowerCore Filter. Then, simply reinstall the filter into the Volant Air Intake.
If you experience a sudden decrease in mileage or engine performance, the filter will need to be replaced.
DO NOT WASH or OIL!
Washing or oiling a PowerCore Filter will ruin it. Both instances require immediate replacement!

Reference for Replacement Filters:

|

|

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MAXFLOW 5 Filter
P/N 5117| DryTech 3D Filter
P/N 5117D| PowerCore®Filter
PN: 61512

PowerCore® is a registered tradename of Donaldson Company Inc.

INS15953-1
08/11/2023
140 Blaze Industrial Parkway, Berea, OH 44017
[email protected]
P: 440.891.0999
F: 440.891.1868
www.volant.com

Documents / Resources

| Volant PERFORMANCE 15954-D-6-1 Closed Box Air Intake [pdf] Instruction Manual
15954-D-6-1 Closed Box Air Intake, 15954-D-6-1, Closed Box Air Intake, Box Air Intake, Air Intake, Intake
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