The installation of a cold air intake (CAI) system is a critical modification for improving engine performance in vehicles. This article provides detailed, step-by-step instructions for installing the JLT cold air intake system, based on information from official installation guides and technical documentation. The process involves the removal of the stock intake, preparation of the airbox and throttle body connections, and the final securing of all components. The instructions are specific to vehicles such as the Chrysler 300, Dodge Challenger, and Dodge Charger, with variations in installation steps depending on the vehicle model and throttle body size.
Pre-Installation Considerations
Before beginning the installation, it is essential to inspect the existing intake system and ensure that all tools and components are available. The installation process involves cutting, adjusting, and securing various parts, so the correct tools and materials must be on hand. The following items are required for the installation:
- 5/16 or 8mm socket/nut driver
- Flathead screwdriver
- X-Acto knife or utility knife
- Hose clamps (specific sizes as required)
- Mounting grommets and edge trim
- Intake tubes (AL1410-00 for stock throttle bodies and AL1459-00 for 108mm throttle bodies)
- 5/8" ID grommet and 5/8" barbed elbow
- The JLT intake system components
- A QR code for the Installation Instructions (to be provided to the vehicle owner)
It is also recommended to keep all stock parts, including the original intake system components, in case they are needed for future reinstallation or troubleshooting. This ensures that the vehicle can be returned to its original configuration if necessary.
Removal of the Stock Intake System
The first step in the installation process is the removal of the stock intake system. This involves disconnecting various components and loosening or removing fasteners to allow for the removal of the airbox and intake tubing.
Disconnect the IAT Sensor: Locate and disconnect the intake air temperature (IAT) sensor from the airbox. This sensor is typically connected via a wiring harness and must be carefully removed to avoid damaging the wiring.
Remove the Airbox Mounting Screw: Use a 5/16 or 8mm socket/nut driver to remove the screw that secures the airbox to the vehicle. This allows for easier access to the internal components of the airbox.
Loosen the Hose Clamp: Locate the hose clamp that connects the stock intake to the throttle body. Loosen this clamp to prepare for the removal of the intake tubing.
Cut the Corrugated Hose: Using an X-Acto knife or utility knife, cut the corrugated hose connected to the stock intake at the end that is connected to the vehicle. Be careful not to damage the barbs on the fitting, as these are important for the proper connection of the new intake system.
Unfasten the Coolant Tank Screws: On some models, it may be necessary to unfasten the two screws that hold the coolant tank in place. This provides additional clearance for the removal of the stock intake system.
Remove the Headlight Scoop (if applicable): For Dodge Challenger models, the headlight scoop connected to the airbox must be removed. This can be done by carefully disconnecting it from the airbox. For Dodge Charger models, the stock headlight scoop can remain in place by pinching the end of the tube so it unsnaps from the box.
Remove the Stock Intake System: Once all connections have been loosened or removed, the stock intake system can be taken out of the vehicle. This includes the airbox, intake tubing, and any associated components.
Installation of the JLT Intake System
After the stock intake system has been removed, the JLT intake system can be installed. The installation process involves positioning the new components, making necessary adjustments, and securing all fasteners and hose clamps.
Install Edge Trim on the Airbox: Before installing the JLT intake system, it is recommended to install the edge trim on the top and bottom of the airbox. This helps to prevent the edge trim from bunching up during installation. To make the process easier, small relief cuts can be made at the hard bends of the trim.
Mounting Prong Grommet Installation: Install the mounting prong grommet on the underside of the airbox. This grommet is used to secure the intake tube and should be positioned correctly to ensure a proper fit.
Select the Appropriate Intake Tube: The selection of the intake tube depends on the throttle body size. For stock throttle bodies, use the longer tube (AL1410-00) with the smaller throttle body connection diameter. For 108mm throttle bodies, use the shorter tube (AL1459-00) with the larger diameter. This ensures that the intake system is compatible with the vehicle's engine configuration.
Install the Grommet and Barbed Elbow: Insert the 5/8" ID grommet into the selected intake tube. Then, install the 5/8" barbed elbow into the grommet. This creates a secure connection between the intake tube and the throttle body.
Position the Intake Tube: Carefully insert the intake tube into the filter flange first. This ensures that the filter is properly aligned and that the coupler can be installed on the throttle body without causing any damage. Adjust the filter snap if necessary to avoid unsnapping the filter base during installation.
Adjust and Tighten Hose Clamps: Once the intake tube is in place, adjust and tighten all three hose clamps on the tube. It is important to ensure that the filter and the bead on the tube are aligned on the bottom. This helps to maintain a proper seal and prevents air leaks.
Reinstall the Stock Screw: After the intake tube and hose clamps have been installed, the stock screw at the front of the vehicle should be reinstalled. This screw helps to secure the intake system in place and ensures that it remains stable during operation.
Final Inspection: Before completing the installation, inspect all components to ensure that they are properly positioned and secured. Check all fasteners, hose clamps, and connections to confirm that they are tight and free of any damage.
Post-Installation Procedures
Once the JLT intake system has been installed, it is important to complete a few final steps to ensure that the system functions correctly.
Provide Installation Instructions to the Owner: If the installation is being performed by a professional or an installer, it is recommended to provide the vehicle owner with the QR code for the Installation Instructions. This code can be scanned using a smartphone or other device to access the detailed maintenance and operation procedures outlined in the instructions.
Verify Proper Functionality: After installation, start the vehicle and listen for any unusual noises or vibrations that may indicate an issue with the intake system. If any problems are detected, it is recommended to recheck the installation steps and ensure that all components are properly secured.
Monitor Performance: Over time, the performance of the vehicle may improve due to the increased airflow provided by the JLT intake system. It is recommended to monitor the vehicle's performance and make any necessary adjustments if needed.
Maintain the System: Regular maintenance of the intake system is essential to ensure that it continues to function properly. This includes cleaning the air filter and inspecting the intake components for any signs of wear or damage.
Conclusion
The installation of the JLT cold air intake system requires careful attention to detail and the use of proper tools and techniques. By following the step-by-step instructions outlined in this article, users can successfully install the intake system and enjoy improved engine performance. It is important to inspect all components and ensure that they are properly secured to prevent any issues during operation. Additionally, providing the vehicle owner with the Installation Instructions ensures that they are aware of the maintenance and operation procedures for the new intake system.