Airaid 200-154 Installation Instructions

Installation Instructions

For Part Numbers:

200-154 700-469 Airaid Oiled Media Filter
201-154 701-469 SynthaMax Dry Media Filter - Red
202-154 702-469 SynthaMax Dry Media Filter - Black
203-154 703-469 SynthaMax Dry Media Filter - Blue

2004 Chevrolet Silverado 2500HD/3500HD
2004-05 GMC Sierra 2500HD/3500HD

6.6L V8 Duramax Diesel “LLY”

Component Identification

1. Airaid Premium Filter 1

2. Front Cool Air Dam Panel 1

3. Rear Cool Air Dam Panel 1

4. Filter Adapter 1

5. Airaid Intake Tube 1

6. Urethane Hump Hose 1

7. Urethane Coupler 1

8. Weather Strip 19 ½” 1

9. 6-32 x 5/16” Screw 5

10. #6 Flat Washer 5

11. 6-32 Keps Nut 5

12. ¼-20 x ½” Button Head Bolt 3

13. ¼” Flat Washer 7

14. M6-1x25 Hex Bolt 4

15. 8-32 x ½” Button Head Screw 2

16. #72Hose Clamp 2

17. #60 Hose Clamp 2

18. T20 Security Bit 1

Full color instructions can be viewed on our web site at Airaid.com. Use the Product Search function to find your part number, and click View Details.

1. Disconnect the negative battery cable.
Disconnect the Mass Air Flow (M.A.F.) sensor
wiring harness. Using the supplied T-20 Security
bit, remove the two screws and the M.A.F. sensor
from the tube (save the sensor for reuse). Loosen
the hose clamps on each end of the factory intake
tube assembly.

2. Remove the factory filter minder and grom­met.

3. Remove the factory intake tube assembly
from the engine. Rock the factory air box back
and forth and remove it from the vehicle.
There are only grommets holding it in, no
bolts.

4. Using a 10mm socket, remove the five bolts
and mounting plate from the engine compart­ment.

7. Install the Airaid Cool Air Dam assembly in
the engine compartment using four M6-1x25 hex
bolts (#14) and 1/4” flat washers (#13).

5. Assemble the Airaid Cool Air Dam pan­els (#2, #3) using five 6-32 x 5/16” screws
(#9), #6 flat washers (#10) and 6/32 keps
nuts (#11).

8. Using two 8-32x 1/2” button head screws
(#15) install the factory M.A.F. sensor in the
Airaid intake tube (#5) DO NOT USE THE

FACTORY SCREWS!. (Note: Sensor must
be installed in the direction shown in the pic­ture.)

6. Using three ¼-20x 1/2” button head bolts
(#12) and 1/4” flat washers (#13), install the
filter adapter (#4) onto the Airaid Cool Air
Dam.

9. Install the factory rubber grommet and air
filter minder into the Airaid intake tube.

10. Install the urethane hump hose (#6) and
two #72 hose clamps (#16) onto the large end
of the Airaid intake tube. (Note: Leave hose

clamps loose until final assembly.)

13. Install the Airaid filter (#1) onto the filter
adapter, and tighten the hose clamp. Install the
weather strip (#8) onto the Airaid Cool Air
Dam. Reconnect the MAF sensor wiring har-
ness. (Note: Start from one corner and work

your way around to insure proper alignment
of the weather strip.)

11. Install the urethane coupler (#7) and two
#60 hose clamps (#17) onto the small end of
the Airaid intake tube. (Note: Leave hose

clamps loose until final assembly.)

12. Install the Airaid intake tube assembly
onto the engine. Install the hump hose end
onto the filter adapter first and then slip the
coupler end of the tube onto the aluminum
intake tube. Adjust for fit, and tighten the hose
clamps. (Note: There should be a gap in be-

tween the Airaid intake tube and the air filter
adapter.)

14. Double check your work!

Make sure there is no foreign material in the intake path. Make sure all clamps, hoses, bolts, and
screws are tight.

15. Reconnect the negative battery cable!

WARNING! If your vehicle has a Vehicle Emission Contr ol Infor mation decal affixed to the factor y air box, a new r eplacement label must

be obtained and installed in a readily visible position in the engine compartment in order to remain CARB compliant. Failure to do so will prevent
the vehicle from passing a smog check. Replacement labels can be ordered from your local dealership. Regulations state that the VECI label shall
not be affixed to any equipment which is easily detached from the vehicle. Label placement, under the hood on a painted surface is recommended.

Thank you for purchasing the Airaid Intake System. Contact Airaid @ [phone] 8:00 AM - 5:00 PM MST weekdays for questions
regarding fit or instructions that are not clear to you. Your Airaid Intake System was carefully inspected and packaged. Check that no parts are
missing, or were damaged during shipping. If any parts are missing, contact Airaid. The air filter element is protected from direct exposure to wa­ter and debris; care should be taken not to drive through deep water. WATER INGESTION IS THE DRIVERS RESPONSIBILITY! The air filter
is reusable and should be cleaned periodically.

FILTER IDENTIFICATION

700-469 Airaid Oiled Media 701-469 Airaid SynthaMax Dry Media - Red

702-469 Airaid SynthaMax Dry Media - Black 703-469 Airaid SynthaMax Dry Media - Blue

For your Oiled media filter we

suggest using the AIRAID Filter

Tune-Up Kit!

P/N 790-551 Aerosol Spray
P/N 790-550 Squeeze Spray

Airaid Filter Co. 2688 E Rose Garden Ln. Phoenix AZ 85050 [phone] [e-mail] www.airaid.com

Synthamax Air Filters do not require oil.
Service air filter as needed by cleaning
with common non-petroleum all-purpose
household cleaner and water. Simple
Green®, Formula 409® or equivalent
works great. Apply cleaner to outside of
air filter and allow to soak. Then flush
filter clean from the inside out with a gar­den hose and repeat steps if necessary.
Do not apply high pressure water or air
to clean filter. Allow filter to air dry and
reinstall.

REV.11.13.13