aFe Power 77-42008 User manual

advanced FLOW engineering
Instruction Manual P/N: 77-42008 SCORCHER HD Module
Make: Dodge/RAM Model: 2500/3500 HD Year: 2007.5-2012 Engine: L6-6.7L (td) Cummins

Label Qty. Description Part Number
A 1 Module R77-42008
B 1 LED Switch 05-70005
C 2 Velcro (2 Inches) 05-01244
D 4 Cable Ties 05-60167
E 1 Shim, Kit 03-50504
• Please read the entire instruction manual before proceeding.
• Ensure all components listed are present.
• If you are missing any of the components, call customer support at 951-493-7100.
• Ensure you have all necessary tools before proceeding.
• Do not attempt to work on your vehicle when the engine is hot.
• Disconnect the negative battery terminal before proceeding.
• Retain factory parts for future use.
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A
B
C
D
E

Refer to Figure A for Step 1.
Step 1: Locate the MAP and Fuel Pressure sensor. The Fuel Pressure sensor 1 is located at the end of
the fuel rail close to the firewall. The MAP sensor 2 is located on the intake manifold under the
EGR.
REMOVAL
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1
2
Figure A

Refer to Figure B for Steps 2-3.
Step 2: Locate and disconnect the fuel pressure sensor
Step 3: Locate the fuel pressure sensor jumper harness on the aFe module. This is the shorter harness
with a small black/orange connectors. Plug the male connector of the module to the stock
fuel pressure sensor, then take the female connector of the module and connect to the male
connector of the engine harness.
Note: Make sure connections are fully engaged. Usually, connectors make a snapping
sound.
Figure B
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INSTALL

Refer to Figures C for Steps 4-5.
Step 4: Disconnect the MAP sensor.
Step 5: Locate the MAP sensor jumper harness on the aFe module. This is the longer harness with a
large grey/orange connector. Plug the female connector of the module to the male connector of
the engine harness, then the male connector of the module to the stock map sensor of the
engine.
Figure C
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INSTALL

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Refer to Figure D for Steps 6-7.
Step 6: Remove the engine cover by taking off the four 8mm screws 3 and taking out the oil dip stick.
Step 7: Remove the 10mm screw 4 holding the dip stick tube and tilt the tube away from the fuel rail to
gain access to the fuel relief valve.
Figure D
3
4
INSTALL
3
3
3

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Refer to Figure E for Steps 8-9.
Step 8: Remove the v-band clamps off the EGR 5 tube in front of the valve cover and rotate away from
the intake manifold.
Step 9: Remove the six 10mm bolts 6 securing the intake manifold and move away from the fuel rail to
gain access of the fuel relief valve.
Figure E
INSTALL
5
6 6
6 6
6
6
5

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Refer to Figure F for Step 10.
Step 10: With an 18mm wrench remove the fuel relief valve 7 .
Figure F
INSTALL
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Refer to Figure G for Steps 11-13.
Step 11: Thread the removal tool onto the fuel relief valve.
Step 12: Place the tip of the fuel relive valve on the edge of a vise and tighten.
Step 13: Turn the removal tool clockwise towards the vise to split the fuel relief valve.
Note: Be cautious and hold the end of the fuel relive valve it is spring loaded and not
mixing the components alignment is very important. Located behind the 3 hole washer is
a very small pin that should not be moved or lost, losing it will cause the vehicle to not
start.
Figure G
INSTALL