Ford - Excursion - Parts Catalogue - 2003 - 2007

57-2546-1 FORD 2003-07 F250 / F350 / F450 / F550 Super Duty 2003-05 Excursion V8-6.0L Turbo Diesel NOTE: This kit was not designed to fit vehicles with a body lift TOOLS NEEDED: Flat Blade Screwdriver 10mm Socket Long Extension 7/16 Wrench Ratchet 7/16 Socket 4mm Allen 2.5 Allen Drill 5/8” Drill Bit X A B A PARTS LIST: Description A B C D E F G H Hose Clamp #64 Silicone Hose Intake Tube Bolt; Buttonhead Allen Gasket Spacers Hose Clamp #60 Saddle Bracket Qty. Part # 4 2 1 2 1 2 3 1 08645 08761 087093 07793 09068 06530 08628 078855 I J K L M N O P Bolt; 6mm F/H/A Cup Washer Washer 1/4 Flat Nut 6mm Nylock Bracket Edge Trim 20” Side Mount Edge Trim 57” Heat Shield 1 1 10 2 1 1 1 1 08376 08180 08275 07553 07174 102476 102470 074006 Q R S T U V W X Nut 1/4”-20 Nylock Bolt 1/4”-20x3/4” Hex Bracket Washer 1.5”ODX.1/4”ID Washer 1/4 Lock Bracket; Lg. “L” Stud Rubber Mntd. Grommet; 1-3/4”OD,1”ID,1/2”. 6 4 1 4 2 1 2 1 07517 08386 07175 21714 08198 07177 070226 082000 Y Z AA AB AC AD Air Filter Bracket; Twist Block Off Plate Wrench; Torx T20 T/R, l-Key Hose; 4”IDX3”L, Hump Intake Tube 1 1 1 1 1 1 RC-5178 07176 21519 69801 08418 087193 IMPORTANT: Service air filter according to the K&N® cleaning instructions (99-5050) when the indicator on the restriction gauge is in the 50 to 65% range. On vehicles that come with an electric restrictor gauge, you must read the gauge manually, do not wait until the dash light illuminates. Do not run the vehicle with the indicator above the 65% range, as damage to the air filter and or the engine could result. If you need any assistance please call 1-800-858-3333 to speak with a representative in our Customer Service Center before returning the product. NOTE: FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS AND NOT USING THE PROVIDED HARDWARE MAY DAMAGE THE INTAKE TUBE, THROTTLE BODY AND ENGINE. TO START: 1. Turn off the ignition and disconnect the negative battery cable. NOTE: Disconnecting the negative battery cable erases pre-programmed electronic memories. Write down all memory settings before disconnecting the negative battery cable. Some radios will require an anti-theft code to be entered after the battery is reconnected. The anti-theft code is typically supplied with your owner’s manual. In the event your vehicles’ anti-theft code cannot be recovered, contact an authorized dealership to obtain your vehicles anti-theft code. 2. Disconnect the restrictor gauge electrical connection as shown. 3. On vehicles equipped with a mass air sensor, disconnect the mass air electrical connection as shown. 3a. On vehicles equipped with an air temperature sensor, disconnect the air temperature sensor electrical connection as shown. 4. Release the four clamps that retain the front and back ends of the air box. 5. On vehicles equipped with a two piece inlet tube and bellows, loosen the hose clamp that secures the turbo inlet tube to the inlet bellows. Continued INSTALLATION INSTRUCTIONS 5a. On vehicles equipped with a one piece inlet tube and bellows, loosen the hose clamp securing the inlet tube and bellows to the air box assembly. 9a. On vehicles equipped with a one piece inlet tube and bellows, loosen the hose clamp that secures the inlet tube and bellows assembly to the turbo inlet. 12. Remove the valve cover nut that retains the dip stick to the engine block with a 10mm socket. 13. Assemble the bracket and saddle as shown. 6. On vehicles equipped with a two piece inlet tube and bellows, loosen the hose clamp at the mass air sensor and remove the intake hose from the vehicle. 9b. On vehicles equipped with a one piece inlet tube and bellows, using a large screwdriver, pry up on the crank case vent fitting in the valve cover to disengage it from the valve cover. NOTE: Use CARE when disengaging the crank case vent fitting from the valve cover so it is not damaged. 14. Install the saddle bracket assembly onto the engine block and secure with the nut removed in step 12. 7. Remove the filter housing from vehicle as shown. 9c. On vehicles equipped with a one piece inlet tube and bellows, remove the inlet bellows and tube assembly from the vehicle as shown. 15. On vehicles equipped with a two piece inlet tube and bellows, install the silicone hump hose (08418) onto the stock turbo inlet tube and secure with the provided hose clamp as shown. 8. Remove the air box base as shown. 10. Remove the rubber grommets that retain the air box assembly onto the vehicle. 15a. On vehicles equipped with a one piece inlet tube and bellows, install the silicone hose (08761) onto the turbo inlet and secure with the provided hose clamp. 9. Remove the air box top as shown. NOTE: K&N Engineering, Inc., recommend that customers do not discard factory air intake. 11. Install the rubber mounted stud onto the air box mounting bracket with the provided hardware as shown. 15b. On vehicles equipped with a one piece inlet tube and bellows, cut the band clamp that secures the crank case vent tube to the turbo inlet tube. Then remove the crank case tube assembly from the turbo inlet tube as shown. Continued INSTALLATION INSTRUCTIONS 15c. On vehicles equipped with a one piece inlet tube and bellows, install the provided grommet into the turbo inlet tube as shown. 15d. On vehicles equipped with a one piece inlet tube and bellows, install the crank case vent tube assembly removed in step #15b into the grommet in the turbo inlet tube as shown. 15e. On vehicles equipped with a one piece inlet tube and bellows, install the turbo inlet tube assembly onto the turbo. Rotate to align the crank case vent tube with the valve cover vent port. Snap the crank case vent tube into the valve cover vent port and secure the tube with the provided hose clamp. 18. On vehicles equipped with a mass air sensor, remove the mass air sensor from the factory air box lid with the provided torx wrench as shown. 18a. On vehicles equipped with an air temperature sensor, remove the air temperature sensor and grommet as shown. 19. On vehicles equipped with a mass air sensor, remove the factory O-ring from the mass air sensor as shown. 20. On vehicles equipped with a mass air sensor install the provided gasket onto the mass air sensor with the sticky side down. 21b. On vehicles equipped with an air temperature sensor, install the mass air block off plate onto the K&N® intake tube using the provided screws and spacers as shown. 21c. On vehicles equipped with an air temperature sensor, drill a 5/8”hole at the drill point on the K&N® intake tube as shown. 21d. On vehicles equipped with an air temperature sensor, install the factory grommet and air temperature sensor into the hole that was drilled in the previous step. 22. Install the K&N® intake tube onto the turbo inlet with the provided hose clamp. 16. Remove the air filter restriction gauge and grommet from the factory air box. 21. On vehicles equipped with a mass air sensor, install the mass air sensor into the K&N® intake tube with the provided screws and spacers as shown. 23. Secure the K&N® intake tube to the saddle bracket with the provided hose clamp as shown. 17. Install the factory grommet and restriction gauge into the K&N® intake tube as shown. 21a. On vehicles equipped with an air temperature sensor, install the provided gasket onto the mass air block off plate as shown. 24. Reconnect the restrictor gauge electrical connection as shown. INSTALLATION INSTRUCTIONS Continued 25. On vehicles equipped with a mass air sensor, reconnect the mass air sensor electrical connection as shown. 25a. On vehicles equipped with an air temperature sensor, reconnect the air temperature sensor electrical connection as shown. 29. Install the heat shield assembly onto the vehicle as shown. 30. Mount the heat shield onto the rubber mounted stud and then secure the long “L” bracket onto the air box mount with the provided bolt and washers. 33. Install the provided bracket onto the radiator mount stud and the air filter stud with the provided hardware. 34. Reconnect the vehicle’s negative battery cable. Double check to make sure everything is tight and properly positioned before starting the vehicle. 35. The C.A.R.B. exemption sticker, (attached), must be visible under the hood, so the emissions inspector can see it when the vehicle is required to be tested for emissions. California requires testing every two years, other states may vary. 36. It will be necessary for all K&N® high flow intake systems to be checked periodically for realignment, clearance and tightening of all connections. Failure to follow the above instructions or proper maintenance may void warranty. 26. Install the edge trim onto the heat shield as shown. Trim if needed. 31. Install the provided rubber mounted stud onto the K&N® air filter as shown. ROAD TESTING: 1. Start the engine with the transmission in neutral or park, and the parking brake engaged. Listen for air leaks or odd noises. For air leaks secure hoses and connections. For odd noises, find cause and repair before proceeding. This kit will function identically to the factory system except for being louder and much more responsive. 2. Test drive the vehicle. Listen for odd noises or rattles and fix as necessary. 27. Install the edge trim onto the inner hole on the heat shield as shown. Trim if needed. 31a. Install the provided silicone hose (08761) onto the air filter flange and secure with the provided hose clamp. 3. If road test is fine, you can now enjoy the added power and performance from your kit. 4. K&N Engineering, Inc., requires cleaning the intake system’s air filter element every 100,000 miles. When used in dusty or off-road environments, our filters will require cleaning more often. We recommend that you visually inspect your filter once every 25,000 miles to determine if the screen is still visible. When the screen is no longer visible some place on the filter element, it is time to clean it. To clean and re-oil, purchase our filter Recharger® service kit, part number 99-5050 or 99-5000 and follow the easy instructions. 28. Install the two brackets onto the heat shield with the provided hardware as shown. Do not tighten completely. 32. Install the air filter element onto the intake tube as shown. NOTE: Adjust all brackets and the heat shield to obtain maximum clearance along the sides and under filter, then secure the air filter. *FREE K&N® decal To register your warranty, please see us online at knfilters.com/register. FREE K&N® decal* • 1455 CITRUS ST., P.O. BOX 1329, RIVERSIDE, CA., U.S.A. 92502 • TECH SERVICE 800-858-3333 • FAX 951-826-4001 • E-MAIL: [email protected] • WWW: HTTP://WWW.KNFILTERS.COM 170007Q 10/13/16