Monster Exhaust System Installation:
1. Disconnect the negative (ground) cable from the battery (if there is more than one battery, disconnect both negative cables). Secure the cable so it cannot accidentally come in contact with the post.
2. Raise the vehicle and support it securely with properly weight-rated safety stands, ramps or a commercial hoist. Take care to balance the vehicle to prevent it from slipping or falling. When using ramps, be sure the wheels are centered squarely on the topsides. Place the transmission in park (automatic), set the parking brake and securely block the wheels that are on the ground.
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These instructions are based on my experience with removing and cleaning the throttle body and from information obtained from the 2000 Durango Factory Service Manual. They were originally my notes for use when I have to do it again. They are as complete and detailed as I can make them, however they are provided for informational purposes only and you should follow or use them at your own risk! Other year models may be different; other engines ARE different. If something on yours seems different, it may well be! Use your head and be careful.
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The ES177C2(-S) Series Floating Actuators are direct-mount, spring return electric actuators that operate on AC/DC 24 V power. These bidirectional actuators do not require a damper linkage and are easily installed on dampers with 1/2 to 3/4 in. or 12 to 19 mm round shafts, or 3/8 and 1/2 in. or 10, 12, and 14 mm square shafts using the standard shaft clamp included with the actuator. An optional M9220-600 Jackshaft Coupler Kit is available for 3/4 to 1-1/16 in. or 19 to 27 mm round shafts, or 5/8 and 3/4 in. or 16, 18, and 19 mm square shafts.
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Removal of Original System
1) Start under the vehicle. Remove the band clamp that holds the stock system to the turbo by loosening the bolt and prying the clamp loose. Save the band clamp for reuse.
2) Cut the original system just behind the muffler and next to the front cross member.
3) Spray the stock hangers with aerosol lube and pry rubber mounts from the system. Leave the rubber mounts attached to the truck for re-use.
4) Remove the old system.
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FRONT INSTALLTION INSTRUCTIONS
1. Block the rear wheels of the vehicle. Raise the front of the vehicle and support the vehicle with jack stands under the frame rails. Remove the front wheels and tires and set aside. Position a hydraulic jack under the front axle and raise the jack until the front suspension begins to compress.
2. On both sides of the vehicle, scribe alignment marks on the adjustment cam and axle bracket at the lower link to axle attachment point for later reference. See Photo 1
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The AirDog® Fuel Air Separation system is a Premium replacement lift pump and filtration system for the Dodge Cummins diesel engine. A complete installation kit is included. The AirDog® delivers clean fuel to the engine free of virtually all air/vapor and at a positive flow. Thus, allowing the engine “test cell” performance and efficiency, while in “real world” use. The AirDog® FP-100 flows 100 GPH and is recommended for stock and slightly modified 6.7L Cummins Diesels up to 550 HP. The AirDog® FP-150 is recommended for highly modified 6.7L Cummins Diesels up to 1,200+ HP. PureFlow products are manufactured with a personal touch, unsurpassed attention to detail and the most stringent quality control.
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1. Module Installation: You will need to run the wiring harness thru the firewall and attach your power module to the harness inside the cab of your truck. Place the module under the dash out of the way
of your pedals.
2. Data Link Connection: The Data Link connector is located in different locations based on the year of the truck.
98.5-99: The triangle shaped connector is located on the driver’s side of the engine in the wiring harness near the power steering pump.
2000-2002: The three prong flat connector is located on the top of the fuel lift pump that is located on the driver’s side of the engine directly below the map sensor.
Note: on some 2001 trucks the connector is located on the driver’s side of the engine in the wiring harness near the power steering pump.
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Turn the front wheels all the way to the left or right for mud guard installation. However, it may be necessary to remove the wheels depending on the tools being used for installation.
1. Clean and degrease the mud guard location area on the fender before installation.
2. Using the mud guard as a template, position and mark hole location B with a marking utensil. Make sure the mud guard fits flush against the front fender and is parallel to the ground (figure 1).
3. Center punch and drill 1/8” hole at location B.
4. Attach mud guard to front panel with #10 screw, check fit and alignment. Adjust accordingly.
5. Center punch and drill 1/8” holes at locations A, C and D using the mud guard as a template.
6. Install #10 screws at locations A, C and D, check fit and tighten.
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The Police Upfitter’s Guide has been prepared with the assistance of service and engineering specialists to assist vehicle upfitters in achieving the highest standards of safety and quality in their products. This guide is divided into topics pertinent to upfitters of police vehicles. References are made to the 2008 Dodge Charger and Magnum Service Manual for appropriate service procedures, torques specifications, component separation clearances, and other standard information that is common with the unmodified vehicle.
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LIGHT BAR CUTTING INSTRUCTIONS
1. Two people will be needed to complete this task.
2. Place ONLY THE MOUNTING END CASTING into the rain-gutters of your vehicle.
3. Level each Mounting End Casting so that the top flat area is parallel to the horizon.
4. Take a tape measure and measure the distance between each open end of each Mounting End Casting .
5. Add 2 inches to that dimension.
6. Subtract that total from the total length of the bar, which is 56″.
7. Take the difference and divide it by two.
8. The amount divided by two is the amount you will cut off each end of your bar.
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