Rock Ripper Extreme Air Intake

Tools Needed:

• Flathead Screwdriver
• Drill & 1/4" Drill Bit
• Ratchet & Socket set
• Adjustable Wrench

Installation Notes:

1. Read all instructions completely and carefully before you begin.

2. Check to make sure the kit is complete and that no parts are missing. If anything is missing, please contact Trail-Gear at (559) 252-4950.

3. Park vehicle on a clean, dry, at, level surface and block the tires so the vehicle can not roll in either direction.

4. Any variation from these instructions or parts will void the 50-state smog legal certification.

Installation Instructions:

1. Disconnect the Mass Airflow Sensor harness from the Mass Airflow Sensor.

3. Unbolt and remove the entire Air Cleaner Assembly and Intake Air Connector from the vehicle. Unbolt the Mass Airow Sensor from the Air Cleaner Cap. Save the Mass Airflow Sensor and rubber gasket for re-installation.

4. Position the new Air Intake Bracket into the stock Air Cleaner’s mounting location. Align the long mounting leg of the new Air Intake Bracket with the original Air Cleaner’s rear mounting hole. Mark this location on the Air Intake Bracket. Remove the Air Intake Bracket and drill a 5/16” diameter hole in the marked location on the Air Intake Bracket. Note: It might be necessary to mock up the Stainless Steel Air Tube, Cast Aluminum Air Tube, & Silicone Adapters in order to position the Air Intake Bracket correctly.

5. Position the Air Intake Bracket back into the vehicle and secure using the stock bolt or the M8 Bolt & 5/16” Washer provided.

6. Align the steel Support Bracket with the mounting hole in the Air Intake Bracket and against the flat spot on the inner fender panel. Mark the location and drill a 9/32” diameter mounting hole at the marked location on the inner fender panel. CAUTION: The Windshield Wiper Fluid Reservoir is directly under the inner fender. Use care to avoid drilling into the Windshield Wiper Fluid Reservoir. Note: In some instances, the support bracket may need to be slightly bent to align with the fender panel correctly.

7. Attach the Mass Airflow Sensor & rubber gasket removed in Step 3 to the back of the Air Intake Bracket using (4) of the ¼” bolts and nuts provided.

8. If the vehicle is installed with a charcoal canister, install the Nylon 3/8” Barbed x ½” NPS Fitting into the corresponding ½” NPS hole in the Air Intake Bracket. If the vehicle is not equipped with a charcoal canister, install the ½” NPS plug into the ½” NPS hole in the Air Intake Bracket.

9. Mount the Air Intake Bracket and the Support Bracket back into the vehicle and secure using the remaining (2) ¼” Bolts & Nylock Nuts.

10. Install the remaining ½” NPS plug into the Cast Alumi-num Tube. A small amount of Loctite or RTV (not included) can be applied to the threads prevent the plug from vibrating loose. Wipe any excess Loctite or RTV from the inside of the Cast Aluminum Tube.

11. Install the Stainless Steel Air Tube, Cast Aluminum Air Tube, Silicone Adapters, Fittings, & Hose Clamps per the diagram below. Note: If the stock hose coming from the Charcoal Canister is too short, replace it with the 11” long piece of 3/8” I.D. Rubber Tubing provided and secure it to the 3/8” Barbed Fitting on the Air Intake Bracket using the 5/8” Hose Clamp provided.

12. If needed, secure the wiring harness to the Stainless Steel Air Intake Tube using the (3) 11” Wire Ties provided.

13.Install the Air Filter onto the Air Intake Bracket and secure the hose clamp provided on the Air Filter.

14. Connect the Mass Airflow Sensor Harness to the Mass Airflow Sensor.

15. Apply the provided C.A.R.B. decal to the underside of the hood, near the Toyota Vehicle Information Label.

17. As needed, wash & re-oil the Air Filter using a commercially-available reusable filter recharger kit.