Bully Dog RAPID FLOW Cold Air Intake User manual

Applications RFI Part Number
Chevrolet Silverado 6.2L‘14+
GMC Sierra 6.2L‘14+
GMC Yukon 6.2L‘15+
GMC Yukon XL 6.2L‘15+
Cadillac Escalade‘15+
53255
INSTALLATION MANUAL
Not legal for sale or use in California on pollution-controlled vehicles.
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TROUBLESHOOTING:
Before Calling Technical Support complete the following
steps:
•Visit bullydog, click on the Support tab located at the
top of the page and the select “technical support” from the
dropdown menu.
•If you questions aren’t anwered in the FAQ’s list, click on
chat with a tech and fill out the required information.
•All of the blank boxes must be filled out, including
Company. If you wish, just type in“none”under Company.
INTRODUCTION ..........................................................................................................PG. 1
PARTS INCLUDED........................................................................................................PG. 2
PARTS DESCRIPTION ..............................................................................................PGS. 3-7
INSTALLATION .................................................................................................... PGS. 8-18
REMOVING THE STOCK AIR INTAKE................................................................ PGS. 8-13
PREPARING TO INSTALL THE RFI INTAKE...................................................... PGS. 14-15
INSTALLING THE RFI ON THE VEHICLE.......................................................... PGS. 16-18
FILTER MAINTENANCE ..............................................................................................PG. 19
PREFILTERS..............................................................................................................PG. 20
REPLACEMENT CONE FILTER .......................................................................................PG 21
Table of Contents
INTRODUCTION
This instruction set outlines the installation and maintenance of the Stage 2 Rapid Flow Cold Air
Intake for all GM 6.2L gasoline powered pickups. Installation of this intake takes about 20 minutes,
requires little mechanical experience and can easily be performed in a driveway even by those who
have never installed an intake on a vechicle before.
TABLE OF CONTENTS

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Parts Included
Parts Included and Tools Needed:
This section displays the parts included in the package and the tools needed to properly
install the system.
Parts Included
RFI Base (53102-2)
RFI Lid (53102-1)
Filter Tube w/MAF sensor mount(53254-3)
Stage 2 Intake Tube (53255-4)
Hump Silicone Coupler (53252-5)
Straight Silicone Coupler (53252-6)
(2) Silicone CCV Hose (51201-6)
(2) 4”Band Clamps (51105-7)
(2) 4.5”Band Clamps (53252-7)
(4) #8 Hose Clamps (10800-4)
(2) Stainless black oxide MAF screws
(54100-94)
Air Filter (224800)
T-15 Torx (53203-94)
(3) M6 Bolt (53254-98)
TOOLS NEEDED
Flat head screw driver
Phillips screw driver
Bit driver
10mm socket
Socket wrench
T15 Torx Bit (included)

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Parts Description:
This section describes each part and any special features of each part that need to be noted
to assist with installation. All parts will be referred to during installation by the names used
in this section.
The RFI base: The base of the RFI enclosure that holds the lter has a couple of features to
note. The rst is the circular hole on the back of the base, this hole is where the RFI tube will
snap into the base and hold secure the air lter. The second important part of the base is the
foam secured to the inlet of the box, which is to seal tightly to the side of the truck.
The RFI Lid: The lid is very easy to remove for lter maintenance, notice the tongue and
grove formed between the housing base and the lid needs to be properly lined up for a good
seal.The latch mounts on the lid should always match up with the latch mounts on the base.
Parts Description

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Lid Latches: The lid latches come pre-assembled onto the RFI base and are used to secure
the lid to the base. This latch system is typical of many OEM style systems and allows for
quick and easy access to the air lter for maintenance and to clean out any debris which
may have collected inside of the lter housing.
Air Intake Tube with MAF mount: The injection molded tube comes with a precisely
manufactured Mass Air Flow sensor mount with inset screw mounts. The tube also has a
unique interference snap t feature that will tightly secure the intake tube to the RFI base.
Notice in the diagram below which end of this tube goes into the RFI base.
RFI base end
Snap t
MAF sensor mount
Parts Description

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Stainless black oxide screws: The two Phillips style stainless black oxide screws included
with the kit are used to secure the MAF sensor to the air intake tube.
Air filter and clamp: The air filter included is an ISO 5011 certified eight layer oil filter.
The air filter is secured onto the end of the air intake tube using the filter clamp and a flat
head screw driver.
Parts Description

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Stage 2 Tube: This tube will replace the stock tube. Notice the smooth free owing design
that will enhance air ow.
Silicone couplers and clamp set: Included in the kit, used to connect the stage 2 tube to
the other parts are two silicone couplers. One strait coupler and one humped coupler. Also
included are four band clamps used to secure all connections.
Parts Description
CCV Recirculation
Connection
Throttle Body Side
MAF sensor
Side
MAF Sensor Side
Throttle Body
Side

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Silicone CCV hose and number 8 hose clamps: This hose connects the CCV breather
tube to the CCV Recirculation Connection on the Stage 2 tube. There are two CCV recircula-
tion connections. The four small #8 clamps are used to secure both ends when installed.
Parts Description

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Installation Overview:
Installation is very simple, it is separated into three parts: Removing the Stock Intake,
Preparing the RFI intake for installation, and Installing the RFI intake system. The complete
installation of the RFI intake system should total about 20 minutes.
Removing the Stock Air Intake:
Follow the steps in this section for guidance on how to remove the stock air intake.
Stock intake overview diagram: The stock intake can be seen in the picture below.
Notice the important parts of the stock air intake that are noted in the diagram below. These
items are referred to throughout these instructions.
Stock Intake overview
Stock Intake Tube
Mass Air Flow sensor CCV Recirculation
Connections
Stock Intake enclosure
Stock Removal

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2. Disconnect the Mass Air Flow sensor plug by rst unlocking the tab (pull the red plastic
away from the plug). Then depress the tab and pull the plug o the sensor.
Removing the stock intake continued:
1. IMPORTANT: Before beginning
Installation, disconnect negative
battery clamps.
Failure to do so could result in
injury or damage to your vehicle.
Stock Removal

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Stock Removal
CCV Connection
Band Clamp
Band Clamp CCV Connection
3. There are four points where the stock tube is connected to something else on the vehicle
(as seen in the image below). All must be properly disconnected to remove the intake tube.
3A. Disconnect the stock CCV recirculation located on either side to the de-resonator
chamber on the intake tube. Disconnect the CCV tube by depressing the grey band then pull
away from the intake tube. Do this on both sides.
Push in to disconnect
CCV Location

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3B. Loosen both band clamps at the throttle body and stock intake enclosure. Once these
are loose remove intake tube.
4. Remove the CCV recirculation tubes that are connected to the engine. Depress the grey
tab and pull away from the engine. There are two tubes to remove.
Stock Removal
Loosen Band Clamp
Remove CCV
recirculation
tubes

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5. The intake enclosure is connected to a plate that sits beneath it by rubber grommets. It
can be easily removed by pulling up on the end of the tube. Carefully remove the entire
lter housing in one piece.
6. Remove stock intake mounting plate by removing 4 10mm bolts.
Stock Removal

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Preparing the RFI intake for installation:
1. Snap the RFI Intake tube into the
intake enclosure, this may take a
bit of pressure. Make sure to insert
the tube from outside to in with
the snaps in front.
2. Carefully remove the MAF
sensor from the stock intake
enclosure, use the T-15 torx bit
(included with the kit) with a bit
driver to remove the torx head
screws holding the MAF in place.
Take very good care of the MAF
sensor while transferring it over
to the Bully Dog RFI.
3. Insert the MAF sensor into the MAF sensor mount on the RFI tube. Use the black oxide
screws included with the kit to secure the MAF sensor to the RFI tube.
RFI Prep

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4. Now gather the 4 large band clamps, the 2 silicone couplers, and the stage 2 RFI tube.
Preassembling these parts will make installing these parts on the vehicle much easier.
When installing the couplers, place the coupler with the hump on the MAF sensor side of
the stage 2 tube and the strait coupler on the throttle body side of the stage 2 intake tube.
Put both couplers onto the stage 2 intake tube and loosely tighten the band clamps over the
coupler, to the point that neither the coupler nor the clamp will fall o while installing this
assembly on the vehicle.
RFI Prep

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Installing the RFI intake:
1. Place the Bully Dog RFI bottom into the engine bay over the spot where the stock lter
housing plate was originally placed, with the RFI MAF tube still installed.
*Using three of the 10mm bolts that Bully Dog supplied, secure the RFI
bottom to the inside of the engine bay.*
IMPORTANT: Do not over-tighten the screws, as this could damage the Bully Dog intake.
2. Install the Stage 2 air intake tube assembly. Move couplers so that the connections are
equal on either side of the couplings before tightening the clamps. Tighten the band clamps
when everything is installed correctly.
RFI Installation

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3. Install the Bully Dog CCV tube on the driver side rst. Tighten #8 clamps when installed.
4. Install the other Bully Dog CCV tube on the passenger side by rst securing it to the
engine. Guide the tube to the Stage 2 intake tube and mark where it should be cut. After
cutting the tube, install and tighten the tube to the Stage 2 intake tube with the #8 clamp.
RFI Installation
Cut Here

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5. Reconnect MAF sensor. Plug in and push down on red tab to lock.
6. Install the air lter over the MAF sensor tube on the inside of the RFI intake bottom.
Position the air lter onto the end of the tube so that the lter points slightly downward
and then tighten the air lter clamp with a at head screw driver. The clamp should be tight
enough that it is very dicult to pull the air lter o of the tube with your bare hands.
RFI Installation

18
RFI Installation
7. Install the RFI Lid onto the RFI bottom and secure the lid using the lid latches.The lid
latches work similar to an OEM style system, simply snapping on.
8. The nal step of this installation is to replace the engine cover and reconnect the battery
terminals.

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Filter Maintenance:
The intake system should be cleaned at least once every three months; in dusty climates the lter
should be cleaned more often. Use a Prelter to extend time between cleaning. Cleaning the intake
is a two part process, the rst part of the process involves the physical cleaning of the lter with soap
and water and the second part involves oiling the lter. To properly clean the lter, a Bully Dog clean-
ing kit should be used. Cleaning kits are available at any Bully Dog
dealer.
PART 1, CLEANING THE FILTER:
1. Remove lter from lter housing. Clean the lter housing if
necessary.
2. Begin the cleaning process by ridding the lter of any dirt by
lightly tapping it.Then brush away any loose particles with a
soft-bristle brush. This step can usually be avoided with the
use of a prelter.
3. Spray cleaner generously over entire lter and let soak for
10 minutes.
4. Thoroughly rinse the lter with regular tap water (avoid
high-pressure hoses). Flush from the inside out or clean side
to the dirty side to prevent dirt from entering the lter.
5. Let the lter air dry before oiling, do not use any method to speed up the drying process. Using
a blow dryer or compressed air can cause the lter to disgure which would then allow particles
to pass through the lter.
PART 2, OILING THE FILTER:
1. Apply a small amount of oil to the soft bristle brush and spread the oil over the lter. Be sure to
apply a small amount of force so not to damage the lter element.
2. Continue applying oil to the lter using a soft bristle brush until the entire lter is covered in an
even amount of oil, just enough to give the lter a solid blue color. Apply enough oil to make the
lter a solid and uniform blue, but do not go beyond that.
3. Allow oil to sit for 20 minutes. Re-oil any dry spots that appear. Do not oil lter excessively. Exces-
sive oiling can cause damage to intake sensors.
Filter Maintenance
# 229000