Glacier Air-Boss 67 Intake Plenum User manual

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Installation Manual
P/N 07510-ABIP
2007.5-10 DODGE CUMMINS
Air-Boss 67 Intake Plenum
Installation Instructions
P/N 07510-ABIP
GDP Air-Boss 67 Plenum Installation
PLEASE READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION

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Air-Boss 67 Intake Plenum Kit Contents
Qty Item Description
1 Air-Boss 67 Billet Intake Plenum
1 Intake Plenum Gasket
1 Intake Manifold Gasket
4 Fuel Rail Spacers
1 Intake Temp Sensor O-ring
Please check your parts inventory against the above parts list
before beginning your installation.

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FUEL RAIL, INJECTOR LINE & STOCK PLENUM REMOVAL
CAUTION: Cleanliness cannot be overemphasized when handling or replacing
diesel fuel system components. This especially includes the fuel injectors, high-
pressure fuel lines and fuel injection pump. Very tight tolerances are used with
these parts. Dirt contamination could cause rapid part wear and possible
plugging of fuel injector nozzle tip holes. This in turn could lead to possible
engine misfire.
Before assembly, examine each part for dirt, grease or other contaminants and
clean if necessary. When installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
1. Disconnect the battery negative cables.
2. Remove the charge air cooler outlet tube connection from the intake manifold.
3. Remove the engine oil dipstick tube mounting bolt.
4. If needed, remove dipstick support at fuel filter housing.
5. Disconnect the air grid heater power cable at the cable mounting stud.
Caution!!! If a grid heater will not be re-installed this wire must also be disconnected at
the relay on the passenger side battery tray to avoid a short circuit!!!
6. Remove the engine wiring harness support bolt from the intake manifold.
7. Remove the six (6) intake manifold mounting bolts.
8. Remove the intake manifold.
9. Remove the high pressure fuel lines and fuel rail.
CAUTION: When loosening or tightening high-pressure lines at the cylinder head,
use a back-up wrench on the crossover tube nut at the head. Do not allow fitting
to rotate. Loss of crossover tube torque will result.
10. When removing fuel line at No. 6 cylinder, a bracket (1) is located above fuel line
connection at cylinder head. Two bolts secure this bracket to rear of cylinder head.
The upper bolt hole is slotted. Loosen (but do not remove) these 2 bracket bolts. Tilt
bracket down to gain access to No. 6 fuel line connection.
NOTE: It is possible to remove only lines 1-4 and gently flex the rail up high enough
to remove the stock intake plenum/grid heater. Caution must be used to not bend
the number 5 & 6 injector lines if this method is used!!!

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11. Remove engine lift bracket (if necessary).
12. Carefully remove each fuel line from engine. Note position of each while removing.
13. Disconnect plenum air temperature sensor connector.
14. Remove the intake plenum air temperature sensor.
15. Remove the remaining intake plenum cover-to-cylinder head bolts.
16. Remove the intake plenum cover and gasket. Keep the gasket material and any
other material out of the air intake!
17. Clean the cylinder head sealing surface.
AIR-BOSS 67 INTAKE PLENUM INSTALLATION
18. Using the new gasket, install the Air-Boss 67 plenum.
19. Install the cover-to-cylinder head bolts that do not hold down the fuel rail. Tighten
the bolts to 18 ft. lbs. torque.
20. Install the intake plenum air temperature sensor. The stock sensor has a crush
washer and can be reused. If you so choose we have included an O-ring to replace
the crush washer on the sensor. To install using the supplied O-ring remove the
stock crush washer by cutting with a pair of wire cutters and roll on the new O-ring.
21. Check torque on the high pressure crossover tube connector nut at the cylinder
head. Torque nut to 50 N·m (37 ft. lbs).
Installing the High Pressure Rail and Injector Lines
22. Position fuel rail on top of the Air-Boss 67 using the four (4) supplied rail spacers.
Install the four (4) mounting bolts and tighten bolts to 24 N·m (18 ft. lbs) torque.
CAUTION: Anytime a high-pressure line is removed from the engine, its fuel
connector nut at the cylinder head must first be retorqued. Refer to Torque
Specifications.
23. Position proper fuel line to proper injector on engine. Tighten fittings hand tight at
both ends of line.
24. Tighten fuel line at cylinder head. Torque nut to 30 N·m (22 ft. lbs).
25. Tighten fuel lines at fuel rail. Torque nut to 37 N·m (27 ft. lbs).

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26. If removed, install engine lifting bracket (1) and bolt. Torque nut to 77 N·m (56 ft.
lbs).
27. Connect the plenum air temperature sensors electrical connector.
28. Using the supplied gasket install the intake manifold.
29. Install oil dipstick tube support at fuel filter housing (if removed).
30. Install the engine oil dipstick tube and mounting bolt.
31. Position the charge air cooler outlet tube onto the air inlet housing. Tighten the
clamps to 100 in. lbs. torque.
32. Attach the engine wire harness to the air inlet housing.
33. Connect the battery negative cables.
34. Prime the fuel system. Start vehicle and check for leaks.
Installation complete! Enjoy the new power and lower EGT’s of the Air-Boss 67 high rise
intake plenum!!!
Glacier Diesel Power, Inc.
glacierdieselpower.com
509-993-4923

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GLACIER DIESEL POWER
DISCLAIMER OF LIABILITY
Other than as expressly set forth herein, Glacier Diesel Power (hereafter collectively, "SELLER") shall in
no way be responsible for the PRODUCT’S proper use and service. In no event shall SELLER be liable
for any special, incidental, indirect or consequential damages of any kind or nature, whether or not
BUYER was advised of the possibility of damage, arising or resulting from the use or performance of the
PRODUCT, and BUYER hereby waives any and all such claims.
BUYER acknowledges that he/she/it is not relying on SELLER’S skill or judgment to select or furnish
goods suitable for any particular purpose and that SELLER has no liability that will extend beyond the
scope of the limited warranty contained herein, and BUYER hereby waives all remedies or liabilities,
expressed or implied, arising by operation of law or otherwise, (including, without limitation, any
obligations of SELLER with respect to fitness for any particular purpose; merchantability; and special,
incidental, indirect or consequential damages) or whether or not occasioned by SELLER'S negligence.
SELLER disclaims any warranty and expressly disclaims any liability for personal injury or damages
related to BUYER’S use of the PRODUCT. BUYER acknowledges and agrees that the disclaimer of any
liability for personal injury is a material term for this agreement and BUYER agrees to indemnify SELLER
and hold SELLER harmless from any claim related to the PRODUCT and its use or performance. Under
no circumstances will SELLER be liable for any damages, liabilities, costs or expenses incurred as a
result of or by reason of the use, performance or sale of the PRODUCT, including, without limitation, any
damages, liabilities, costs or expenses incurred by reason of BUYER’S negligence related to those uses
of the PRODUCT.
SELLER assumes no liability regarding the improper installation or misapplication of the PRODUCT. It is
the installer's responsibility to check for proper installation, and, if in doubt, contact the manufacturer.
LIMITATION OF WARRANTY
SELLER hereby provides the following limited warranty as to description, quality, merchantability, fitness
for any product’s purpose, productiveness, or any other matter of SELLER'S product sold herewith. The
SELLER shall be in no way responsible for the product’s open use and service and the BUYER hereby
waives all rights other than those expressly written herein. This Warranty shall not be extended or varied
except by a written instrument signed by SELLER and BUYER.
The Warranty is Limited to one (1) year from the date of sale and limited solely to the parts contained
within the product's kit. All products that are in question of Warranty must be returned shipping prepaid to
the SELLER and must be accompanied by a dated proof of purchase receipt. All Warranty claims are
subject to approval by Glacier Diesel Power.
Under no circumstances shall the SELLER be liable for any labor charged or travel time incurred in
diagnosis for defects, removal, or reinstallation of this product, or any other contingent expenses.
Under no circumstances will the SELLER be liable for any damage or expenses insured by reason of the
use or sale of any such equipment.
IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT: THE BUYER MAY
PROMPTLY RETURN THIS PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED
PROOF OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM DATE
OF PURCHASE FOR A FULL REFUND. THE INSTALLATION OF THIS PRODUCT INDICATES THAT
THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND
CONDITIONS.