Magnaflow Exhaust Swap

Factory exhaust systems can be very restrictive. An upgraded exhaust system will not only improve power and help with fuel economy but will sound better. For purposes of our test we chose to install a MagnaFlow Turbo-Back Tuner Exhaust System. MagnaFlow's Performance Diesel Systems feature fast-flowing, 4-inch mandrel-bent stainless steel tubing, and a polished 5-inch-diameter stainless steel tip. The MagnaFlow systems incorporate mirror-finished MagnaFlow Performance Mufflers with a straight-through design. Expect significant gains in horsepower, torque, improved fuel economy and a lower EGT (exhaust gas temperature). They come with a lifetime warranty and OEM-style barbed hangers.

The MagnaFlow system	Loosen exhaust turbo clamp
Remove stock exhaust	Tightening MagnaFlow exhaust hangers

Steps to installing this exhaust system
1. Loosen all exhaust bolts. Remove the exhaust turbo clamp. Remove the bolts. Remove the hangers. Remove the stock exhaust including downpipe.
2. Place new downpipe and install clamp. (Note: install clamp very loose right now, just need it to hold the downpipe in place) Install new exhaust components on the hangers.
3. Begin all bolts into the nuts just enough to hold them in. Align the system so it's straight and fits together well.
4. Tighten the nuts and bolts. Tighten the turbo clamp.
5. Start the truck and check for leaks. You'll know if you have a leak. Not only will you be able to see it but you will definitely hear it.

Airaid Intake System

We expected to see results in fuel economy and horsepower gains when we opened up the intake and exhaust.  Having added the MagnaFlow exhaust, we decided to swap out the factory intake and switch it to an Airaid Intake System. The Airaid engineers had their work cut out for them when they set out to improve upon the factory air intake, which is very recent, state-of-the-art factory equipment. The '03-07 6.0-liter engine utilizes an inline air filter that, from the factory, is both restrictive and expensive to replace. At the heart of this Airaid Intake System is their innovative SynthaFlow high-flow (1,406 cfm) filter. The filter is protected from engine heat by an innovative box constructed from heat resistant x-linked polyethylene and topped off with a Cool Air Dam for added flow. Also, incorporated with this kit is a specially designed intake tube that correctly locates the filter for peak performance and improved drivability. All these kits come with an Airaid "no-hassle" warranty.

Before...	Stock airbox removed
Airaid air box going in	After Airaid installed

How to install the Airaid Intake System
1. Disconnect both negative battery cables. Unlatch all four factory clips on the factory air box. Remove factory air filter by separating the inlet and outlet sections of the assembly. The filter is held in place by two rubber grommets on the bottom. (Make sure factory grommets remain in lower air box support.)
2. Disconnect electronic filter restriction gauge (vacuum gauge) connector and remove the restriction gauge, and rubber grommet. (Note: retain these parts for later use.) Remove air filter inlet tube and hose assembly. Use caution when removing these elements, as it is a tight fit. Be careful not to tear the factory insulation around the radiator support.
3. If you have a mass air flow sensor (MAF), you will need to disconnect the electrical connector and removed the two screws using the supplied T-20 security bit, and remove the sensor. Retain the sensor for later use. Using a 5/16" socket loosen the hose clamp on the end of the intake tube. Remove complete factory air filter tube assembly. (Do not remove flexible turbo inlet hose from turbo housing)
4. Install the gasket and sensor (MAF) using 2 (black) 8/32"x5/8" screws. Install the factory grommet and filter restriction gauge. Slide the Airaid filter tube into the factory flexible turbo inlet hose. (Do not tighten house clamp until assembly is complete.)
5. Reconnect the sensor to the factory plug. Install the Airaid Cool Air Box by inserting the long extension of the box into the radiator support. (Make sure the cold air box inlet is not blocked by factory insulation.) Insert air filter adapter into the air box hole.
6. Insert the supplied billet rivets through the airbox, into the factory grommets. Using 4 supplied stainless steel Allen bolts and washers, mount the air filter tube to the airbox.  Tighten the hose clamp on the flexible turbo inlet tube.
7. Install the Airaid premium filter onto the air filter adapter inside of the airbox, and tighten the hose clamp. Install the black panel onto the top of the airbox using 5 supplied stainless steel Allen bolts and washers.
8. Install the supplied weather strip on the top of the panel. Be sure to start at one end of the panel and work to the other end. Spread the supplied hose mount over the radiator overflow house and insert the tab thru the hole in the side of the panel.
9. Make sure intake path is clear of all debris. Check alignment of the Airaid Intake Tube and tighten all clamps, brackets and bolts. Inspect over all work and reconnect both negative battery cables.