Installation Instructions

Block-off Plates and Secondary Air Bypass Module

Before installing this product, please fully read these instructions, and the instructions for installing the bypass-plates. If you have any questions, please contact us before proceeding. Improper installation can result in vehicle electrical system damage, and/or damage to this module itself. The manufacturer assumes no responsibility for its use, or any consequential or inconsequential damages

This module is designed to be installed without requiring cutting or modification of your existing vehicle wiring – it simply plugs into the harness connecting your MAF (Mass Air Flow) sensor to your engine ECM (Electronic Control Module).

AVAILABLE FOR THE FOLLOWING MODELS

ADDRESSES THE FOLLOWING CEL (Check Engine Light) CODES

P1441 – Secondary Air Injection System Switching Valve No 2 Stuck Open Bank 1

P1442 - Secondary Air Injection System Switching Valve No 2 Stuck Closed Bank 1

P1444 - Secondary Air Injection System Switching Valve No 2 Stuck Open Bank 2

P1445 - Secondary Air Injection System Switching Valve No 2 Stuck Closed Bank 2

P2440 - Secondary Air Injection System Switching Valve Stuck Open Bank 1

P2441 - Secondary Air Injection System Switching Valve Stuck Closed Bank 1

P2442 - Secondary Air Injection System Switching Valve Stuck Open Bank 2

P2443 - Secondary Air Injection System Switching Valve Stuck Closed Bank 2

P2444 - Secondary Air Injection System Switching Pump Stuck ON Bank 1

P2445 - Secondary Air Injection System Switching Pump Stuck OFF Bank 1

For codes P1441, P1444, P2440, P2442, you ‘must’ install the exhaust block-off plates.

We highly recommend installation of the block-off plates in all circumstances, but for these 4 codes, the module and the plates are required to prevent these codes.

The module does not required modification or cutting of your existing vehicle wiring, and the module is installed in four simple steps as shown below (note, the photographs are for reference only, your vehicle wiring may differ, however if you can locate your MAF (Mass Air Flow) sensor on the intake near the air filter box, that’s about all you need to know to get this module installed quickly and easily.

STEP 1 – LOCATE THE MAF (Mass Air Flow) SENSOR CONNECTOR: 

The MAF Sensor is located in the air intake system, adjacent to the air filter box. The connector is a snap-on connector with 5 wires, and should easily be seen in the engine compartment.

STEP 2 – REMOVE THE MAF SENSOR CONNECTOR: 

Press down on the tab on the connector and remove it (do not force the connector, it should slide easily off while you’re holding the tab down).

STEP 3 – ATTACH THE BYPASS MODULE TO THE MAF SENSOR CONNECTOR:

Gently press the modules matching MAF Sensor connector onto the MAF Sensor – it only goes on one way, and will ‘snap’ into place when properly installed.

STEP 4 – ATTACH THE BYPASS MODULE TO THE MAF HARNESS:

Locate the original connector you removed in Step 2, and insert it into the mating connector on the bypass module. It only goes in one way, and will ‘snap’ in place when properly inserted.

STEP 5 – INSTALL THE BLOCK-OFF PLATES:

The module can be easily removed from the vehicle be reversing the above steps – this allows you to run your vehicle in street-legal configuration at any time, and to bypass the SAS/AIP system when racing or running off-road.

TOOLS REQUIRED

You’ll need a 10mm wrench, or 10mm socket wrench, and a flat-head screwdriver. You may also need penetrating oil, such as WD-40 or PB Blaster if there is rust present on the studs.

The block-off plates should ONLY be used in conjunction with a SAS/AIP bypass module. Two plates are required for your engine. Note that the 4.7L plates differ from the 5.7L plates – you must have the correct plates for your application!

4.7 Plates	5.7 Plates

The SAS system includes air tubes that connect to the rear of the exhaust manifolds on each side of the engine. The block-off plates fit in between this connection to stop exhaust gasses from backing up into the SAS system when used with a bypass module.

The block-off plates will replace the existing metal gaskets found between the air tubes and the exhaust manifolds.

The plates are slotted for convenience, so it’s not necessary to remove the nuts from the studs; loosening them 2-3 turns should be sufficient. If the nuts don’t easily turn, use caution – if you break off one of the studs, you will have to remove the exhaust manifold from the engine and have the stud replaced! This is a daunting task! If you’re having issues loosening the nuts, try spraying the area with a good quality penetrating oil, and allowing it to sit for an hour or so. If this fails to help, apply more penetrating oil and start the engine and allow it to get hot (10 minutes is plenty of time).

If you decide to take this step, use EXTREME CAUTION, as the exhaust manifold will be extremely hot and WILL CAUSE BURNS! With a hot manifold and penetrating oil as a last resort, you should be able to loosen the nuts. If not, you should contact a mechanic for assistance – do NOT force the nuts, a broken stud in this area is going to be a costly repair! If you do have to warm up the motor to loosen the nuts, make sure to allow the engine to cool back down before proceeding with installing the block-off plates.

On some vehicles, it may be easier to reach the area from underneath. Loosen both nuts on the studs as noted above (it’s not necessary to remove them), and using a flat head screwdriver, gently pry the air tube from the exhaust manifold.

There is a thin metal gasket between the two – it is not necessary to remove this, simply leave it in place. Slide the block-off plate between the gasket and the exhaust header; the plate is slotted to allow it to be inserted without removing the nuts. Once the block-off plate is installed, re-tighten the two nuts, and repeat for the other exhaust manifold.

OPERATING YOUR VEHICLE WITH THE BYPASS MODULE:

The only requirement imposed when using the bypass module is that you must start your engine within 10 seconds of turning the ignition key to the ‘on’ position. The module works by bypassing the thermocouple in the MAF Sensor during the initial 10 seconds of the ignition key being turned to the on.

If you turn on the ignition, and fail to start the engine within 10 seconds, simply turn the ignition key to the off position for at least 1 second before attempting to start the engine again.