Dodge Avenge Installation Guide Dodge Avenger (3.5L)

Transcription

ProZen CAI – Dodge Avenger
Avenge (3.5L)
Installation Guide
Reconnect the vehicle’s
s negative battery cable...16
cable.
Start the engine.................................
........................................................................16
Table of Contents
Introduction ................................................................
......................................................... 2
Intake installation complete..................................................17
complete
10 minutes.
minutes................. 2
Test Drive................................................................
.........................................................17
What you Receive in your ProZen kit ................................
.................................. 3
Filter maintenance .........................................................................17
................................
Remove the stock air box. ................................
.......................................................... 5
Clearance the engine cover ......................................................18
................................
Remove the engine cover. ............................................................
............................ 5
PCV crankcase filter? ..............................................................18
................................
Disconnect negative battery lead ................................
......................................... 6
Suggested tools to modify engine cover......................19
cover
Disconnect the Intake Air Temp Sensor ............................. 6
Example modified engine cover ...........................................20
Place Sensor in a safe place................................
................................................... 8
Installation complete!................................
................................................................20
Disconnect PCV Hose ................................................................
.................................... 8
Other
r ProZen MotorSports Products..............................21
Products
Remove the stock airbox plenum ................................
.............................................. 9
ProZen eBay store................................
....................................................................21
Removing the Stock Airbox ................................
........................................................ 10
Magnuson-Moss Warranty Act ......................................................22
................................
Removing the air horn..............................................................
.............................. 11
Why the MMW Act was created...............................................22
created.
Remove wiring harness clip................................
.................................................. 11
You have some security in your aftermarket parts
................................................................
.................................................................................23
Estimated installation time:
Lift airbox off retaining studs................................
...................................... 12
The removed stock airbox .........................................................
......................... 12
Relocate cable retainer.............................................................
............................. 13
The cleared engine bay ...............................................................
............................... 14
ProZen Intake Installation. ................................
................................................... 14
PCV Valve vacuum lines ...........................................................
........................... 15
ProZen CAI Installation Guide
Page 1
Avenge (3.5L)
Installation Guide
The ProZen CAI air-Intake
Intake system replaces your existing plastic/rubber
pipe with awesome flow and with the lifetime KnN filter. You will
maximize incoming air intake to levels beyond comparison with your
factory air box! With proper maintenance of the K&N filter, you will never
have to buy another filter again.
A 12-15
15 hp boost is common on most air intakes. You should also see an
additional 1-2
2 MPG, depending on how you drive.
Introduction
Thank you for Purchasing the ProZen Cold Air Intake (CAI) specifically
designed for your Dodge Avenger
The ProZen CAI has all emissions fittings, all sensor locations and
connections for a flawless install.
This guide describes the installation of the ProZen CAI for the 3.5L
V6 engine. This CAI will not fit 2.4L or 2.7L engines. A separate guide
describing the 2.4L and 2.7L models is required however this guide may be
used as a guide for the majority of the installation of any ProZen CAI on a
Dodge Avenger.
Other CAI may try to copy ProZen
en intakes. Accept no imitations, when you
pop the hood, you will see style. When
hen you start your vehicle, you will
hear intense air flow.
Estimated installation time:
10 minutes.
Installation of the ProZen CAI will
ill not void warranty, per but check with
Dealer first.
Your Pro Zen Motorsports Air Induction-Intake
Intake System will easily install.
You will have to slightly clearance the engine cover as part of the
installation. Not included in installation time estimate.
The ProZen CAI is a chromed & polished, High flow Air induction intake
System, custom built for the 2008 Dodge Avenger R/T or Chrysler Sebring
with the 3.5L V6.
This intake has a 3" Diameter for the V6 and Mounts to a 9" Authentic KnN
Filter as part of the kit.
Page 2
Avenge (3.5L)
Installation Guide
What you Receive in your ProZen kit
1.
2.
3.
4.
Polished Aluminum tube, grommets and posts installed
K&N Filter with sticker and lifetime warranty detail and clamp
Rubber adapter with 2 clamps
1” clamp for PCV post (may be too small depending upon model)
TOP
Page 3
ProZen CAI – Dodge Avenger (3.5L)
Installation Guide
BOTTOM
Page 4
Installation Guide
Remove the stock air box.
Here's the stock engine:
Remove the engine cover.
It just pulls off several posts:
Page 5
Installation Guide
Disconnect negative battery lead
The first thing you should ALWAYS do when working on an
engine is to disconnect the negative battery terminal. Although
you can't get to the battery very easily on an Avenger, all you
have to do to disconnect it is remove the bolt from the driver's
side shock tower:
Disconnect the Intake Air Temp Sensor
Press with a screw driver on the flat side of the sensor while
pulling out gently to remove the cable.
Page 6
Installation Guide
The sensor can then be removed.
It's just a quarter turn to loosen it, then pull it out. BE VERY
CAREFUL WITH IT. DO NOT TOUCH THE END OF THE
SENSOR.
Page 7
Installation Guide
Place Sensor in a safe place
Place the sensor on a clean towel out of the way in a safe
place, such as on the passenger's seat.
Disconnect PCV Hose
Disconnect
isconnect the PCV hose from the airbox and PCV valve. It
just pulls off:
Page 8
Installation Guide
Then move it out of the way while moving ahead.
Remove the stock airbox plenum
Loosen the clamp on the throttlebody with a flat blade
screwdriver and gently pull to remove:
Page 9
Installation Guide
removal.
Removing the Stock Airbox
Using a 13/32”/10MM socket or box end wrench, remove
r
this
bolt holding the stock airbox to the radiator/grille area.
Loosen the clamp on and end of plenum and gently p
pull
It helps to loosen both ends so loose it can rotate for easier
Page 10
Installation Guide
Removing the air horn
The air horn attaches to the same location using this stud.
Using a flat-head screw driver to help, pry up the plastic
retainer and slide the air horn off of it:
Remove wiring harness clip
There is a metal clip holding a wiring harness to the airbox.
Carefully remove it.. It lifts up and away:
away
Page 11
Installation Guide
Lift airbox off retaining studs
Finally, lift up on the airbox so that it clears these two studs. (It
just pulls off.)
The removed stock airbox
The stock airbox removed.
Page 12
Installation Guide
Relocate cable retainer
Carefully remove the metal cable retainer from the plastic post
Remove the rubber grommet and using the previously
removed bolt, put it back in the hole it was removed from. If
you ever choose to install a CAI airbox, you can use this
mounting location.
Slide the clip into the side of the battery box and esing a black zip tie,
reattach the clip to the wiring harness
Page 13
Installation Guide
The cleared engine bay
ProZen Intake
ake Installation.
Installation
Here's the cleared out engine bay.
Slide the intake coupler over the throttle body and tighten the clamps.
Keep the manifold side away from the throttle:
You will need to make sure at least the pipe clamp closest to the engine is
on the left, like this:
Page 14
Installation Guide
IATS Installation
CAREFULLY install the IATS into that large on the side of the
intake. It should fit snugly. Plug it back in. There is a small
square tab that prevents the sensor from being pushed in too
far. That plastic square tab should be touching the grommet.
PCV Valve vacuum lines
Next, install the vacuum lines for the PCV valve. That valve is HUGE on the
3.5
5 V6, so I had to use a reducer. You may need to purchase a separate
1.5” clamp to fit over the 3.5L tube on some models.
Page 15
Installation Guide
Reconnect the vehicle’s
s negative battery
cable.
Double check to make sure everything is tight and properly
positioned before starting the vehicle.
Secure connections?
Secure all of the connections with clamps and/or zip ties:
Start the engine.
Start the engine with the transmission in neutral or park, and
the parking brake engaged. Listen for air leaks or odd noises.
For air leaks secure hoses and connections. For odd noises,
find cause and repair before proceeding. This kit will function
identically to the factory system except for being louder and
much more responsive. If the check engine light comes on,
your IATS sensor is probably not properly connected.
Page 16
Installation Guide
Test Drive
Intake installation complete
And here it is! The finished intake! Please note that the engine
cover WILL NOT fit back on without some modification. If that
doesn't bother you, leave it alone. I'm going to trim the engine
cover sometime soon and get it to fit.
Test drive the vehicle. Listen for odd noises or rattles and fix
as necessary. If road test is fine, you can now enjoy the added
power and
nd performance from your kit.
Filter maintenance
K&N suggests checking the air filter
lter element periodically for
excessive dirt build-up. When the element becomes covered in
dirt (or once a year), service it according to the instructions on
the Recharger service
rvice kit, part number 99-5050
99
or 995000.
Page 17
Installation Guide
Clearance the engine cover
As you can see in this picture, the intake almost fits. That little
ridge you see there is getting in the way. You must remove the
moulded ridge preventing the engine cover from securing
properly.
straight into the side of the intake. You may need to purchase
longer ¾” PCV tube to fit properly.
PCV crankcase filter?
One possible installation may look like this. Notice this now
uses a separate crankcase filter and no longer connects the
vacuum line to the intake. Purchase a separate ¾” cap to
cover the post for the PCV tube on the intake.
With the
e PCV system arranged like this, you can get the
engine cover most of the way on. (The rear two "snaps" will
engage, and the front passenger side one will engage, as well.
This leaves the front driver's side,, next to the PCV valve.):
If you can't get your engine cover this close, it's probably due
to your PCV system. Recall that the original PCV hose is
parallel to the valve cover and points directly at the driver's
side of the car. Post installation, the PCV tube sshould still be
Page 18
Installation Guide
Suggested tools to modify engine cover
You may try using metal files:
A similar set at a local home supply warehouse should cost
~$6.
$6. Using files (Dremel, Xacto knife, etc.),
etc. whittle down the
ridge until the cover will properly fit over the intake.
intake You will
probably need to remove some plastic, install the
t engine cover
to check tolerances, and then remove it and file some more.
Keep at it until you can securely fasten all 4 "snaps" on the
engine cover. This may generate tiny bits of black plastic.
Page 19
Installation Guide
Make sure you remove all those pieces before doing any te
test
fitting. Use a round file to remove large areas of plastic, then
use the triangular file to smooth things out.
Installation complete!
Example modified engine cover
Here's the finished product:
Make sure all cable clamps are tight. A common problem on
CAI systems will be that the clamps were not properly
tightened. It is recommended that you regularly check the CAI
installation for the first week of use to make sure it has not
shifted.
Page 20
Installation Guide
We hope you enjoy your ProZen Motorsports CAI!
Other ProZen MotorSports Products
http://www.truedualexhaust.com
ProZen eBay store
http://motors.shop.ebay.com/merchant/prozenmotorsports
Pro Zen Motorsports has been in business for 9 years. The
current Headquarters is located in Bardstown, KY.
ProZen started by selling fog lamps on Ebay. It has since
taken off. I got started with the Dakota R/T's in 2000
2000.
You can always reach me on my cell orr email. I will get
back to you.
ProZen Mororsports
Bardstown Kentucky
Rick Gindoy 502-553-0764
0764
[email protected]
Page 21
Installation Guide
Magnuson-Moss Warranty Act
On January 4, 1975, President Ford signed into law the Magnuson
MagnusonMoss Warranty Act, Title 1, 101-112,
112, 15 U.S.C. 2301 et seq. This
act, effective July 4, 1975, is designed to "improve the adequacy of
information available to consumers, prevent deception, and improve
competition in the marketing of consumer products. . . ." The
Magnuson-Moss Warranty Act applies only to consumer products,
which are defined as "any tangible personal property which is
distributed in commerce and which is normally used for personal,
family, or household purposes (including any such property intended
to be attached to or installed in any real property without regard to
whether it is so attached or installed)." Under Section 103 of the Act,
if a warrantor sells a consumer product costing more than $15 under
written warranty, the writing must state the warranty in readily
understandable language as determined by standards set forth by
the Federal Trade Commission. There is, however, no requirement
that a warranty be given nor that any product be warranted for any
length of time. Thus the Act only requires that when there is a written
warranty,, the warrantor clearly disclose the nature of his warranty
obligation prior to the sale of the product. The consumer may then
compare warranty protection, thus shopping for the "best buy." To
further protect the consumer from deception, the Act requires that
any written warranty must be labeled as either a "full" or a "limited"
warranty.. Only warranties that meet the standards of the Act may be
labeled as "full." One of the most important provisions of the Act
prohibits a warrantor from disclaiming or modifying any implied
warranty whenever any written warranty is given or service contract
entered into. Implied warranties may, however, be limited in duration
if the limitation is reasonable, conscionable, and set forth in clear
and unmistakable language prominently displayed on the face of the
warranty.. A consumer damaged by breach of warranty, or
noncompliance with the act, may sue in either state or federal district
court. Access to federal court, however, is severely limited by the
Act's provision that no claim may be brought in federal court if: (a)
The amount in controversy of any individual claim is less than
$25,000; (b) the amount in controversy
ersy is less than the sum or value
of $50,000 computed on the basis of all claims in the suit; or (c) a
class action is brought, and the number of named plaintiffs is less
than 100. In light of these requirements it is likely that most suits will
be broughtt in state court. If the consumer prevails, he is awarded
costs and attorneys' fees. Nothing in the Act invalidates any right or
remedy available under state law, and most suits should proceed on
claims based on both the Code and the Act.
Why the MMW Act was created.
“In
In order to improve the adequacy of information available to
consumers, prevent deception, and improve competition in the
marketing of consumer products, any warrantor warranting a
consumer product to a consumer by means of a written warranty
shall. . .fully and conspicuously disclose in simple and readily
understood language the terms and conditions of such warranty.
Such rules . . . require inclusion in the written warranty of any . . .
exceptions and exclusions from the terms of the warranty.“
Magnuson-Moss Warranty & Federal Trade Commission
improvement Act. Section 2302(a.
Page 22
Installation Guide
You have some security in your aftermarket
parts
You want to upgrade your vehicle with aftermarket
ftermarket equipment, but
you’re worried about putting the vehicle’s warranty at risk. It
It’s no
wonder, how many times have you heard someone at a dealership
say that installing aftermarket equipment automatically voids the
warranty?
? This common misconception has been repeated often
enough to be widely believed, though it is completely
ely false
false.
Fact: Dealers don’t like warranty work, because it pays less than
normal repair work. By promoting the myth that aftermarket
equipment automatically voids warranties, some dealers avoid such
low-paying
paying work. Instead, they attempt to charge customers the
prime service rate for work which iss rightfully done under warranty.
Most vehicle owners are not aware they are protected by federal
law: the Magnuson-Moss Warranty Federal Trade Commission
Improvement Act of 1975. Under the MMW Act, aftermarket
equipment which improves performance does no
not void a
vehicle manufacturer’s original warranty, unless the warranty
clearly and conspicuously states that aftermarket equipment voids
the warranty (Avenger’s does not). Most states have warranty
statutes, as well, which
hich provide further protections for vvehicle
owners.
In other words, a dealer can‘tt wiggle out of his legal warranty
obligation merely because you install aftermarket equipment.
To find out if any aftermarket equipment automatically voids your
vehicle’s warranty, check the owner’s
s manual. It will be under the
sections titled "What is not covered". Your vehicle manufacturer is
simply saying he does not cover the aftermarket products
themselves. He is not saying that the products would void the
vehicle warranty.
Suppose your modified
ed vehicle needs repairs while still under
warranty.. Without analyzing the true cause of the problem, the
dealer attempts to deny warranty coverage. He made his decision
simply based on the fact that you’ve
ve installed aftermarket equipment,
equipment
a convenient way to dodge low-paying
paying warranty work.
Fact: A dealer must prove - not just say - that aftermarket equipment
caused the need for repairs before he can deny warranty coverage
on that basis.
Point out to the dealer the provision of the MMW Act. Require that
he
e explain to you how the aftermarket equipment caused the
problem. If he can’t, or his explanation sounds questionable,
questionable it is
your legal right to demand he comply with the warranty.
If you are being unfairly denied warranty coverage, there is
recourse. The
e Federal Trade Commission, which administers the
MMWAct, monitors compliance with warranty issues. Direct any
complaints to the FTC at (202) 326-3128.
3128.
Page 23

Dodge Avenge Installation Guide Dodge Avenger (3.5L)

Transcription

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