How to Install Roush Cold Air Intake on your F-150

Before installing your ROUSH Cold Air Kit, please read through the entire installation procedure and check to make sure all items are present. Contact ROUSH Customer Service at 1-800-59-ROUSH, 9:00 AM to 5:00 PM EST weekdays, for any questions regarding fitment or instructions that are unclear to you.

LIMIT OF LIABILITY STATEMENT

The information contained in this publication was accurate and in effect at the time the publication was approved for printing and is subject to change without notice or liability. ROUSH Performance Products (RPP) reserves the right to revise the information presented herein or to discontinue the production of parts described at any time.

SAFETY REQUIREMENTS

STOP! READ IMPORTANT SAFETY CAUTIONS AND WARNINGS BEFORE PROCEEDING.

Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of the individual performing the kit installation. Improper installation due to the failure to correctly follow these instructions could cause personal injury or death. Read each step of the installation manual carefully before starting the actual installation.

1. Always wear safety glasses for eye protection.

2. Place ignition switch in the OFF position.

3. Always apply the parking brake when working on a vehicle.

4. Block the front and rear tire surface to prevent unexpected vehicle movement.

5. If working without a lift, always consult vehicle manual for correct lifting specifications.

6. Operate the engine only in well-ventilated areas to avoid exposure to carbon monoxide.

7. Do not smoke or use flammable items near or around the fuel system.

8. Use chemicals and cleaners in well-ventilated areas.

9. Batteries produce explosive gases, which can cause personal injury. Therefore, do not allow flames, sparks or flammable substances to come near the battery.

10. Keeps hands and any other objects away from the radiator fan blades.

11. Keep yourself and your clothing away from moving parts when the engine is running.

12. Do not wear loose clothing or jewelry that can get caught in rotating parts or scratch surface finishes.

13. Allow the engine, cooling system, brakes and exhaust to cool before working on a vehicle.

WORK SAFELY!

Perform this installation on a good clean level surface for maximum safety and with the engine turned off.

Note: Allow engine to cool prior to working under hood to avoid contact with hot engine components.

1. Open the hood of your vehicle and disconnect the brake aspirator hose from the fitting on the clean air tube.

2. Disconnect the PCV line fitting from the clean air tube.

3. Loosen the hose clamp that connects the clean air tube to the airbox lid.

4. Loosen the hose clamp that connects the clean air tube to the throttle body.

5. Remove the clean air tube from the vehicle and transfer the clamps from the take off component to your new ROUSH clean air tube (1150-9B659). Install the new brake aspirator fitting (P2233A) into the grommet on the clean air tube as shown.

6. Disconnect the MAF sensor wiring harness from the MAF Sensor. Note – this connector has a red locking tab on the bottom side of the connector.

7. Un-clip the three (3) upper air box lid clamps. Remove the air box lid and factory air filter from the lower air box tray.

8. Transfer the MAF sensor and fasteners from the factory air box lid to the new ROUSH MAF tube (1111-12B579). Torque bolts to 1.8 – 2.2 Nm.

9. Install the new ROUSH open air filter element (997-473) onto the MAF Tube. Do not tighten clamp, as filter orientation may need to be adjusted once placed in vehicle.

10. Install the two (2) J-clips provided (W520823) onto the airbox lid as shown.

11. Slide the MAF tube and filter assembly through the bottom opening into the new ROUSH air box lid (1111-9A600).

12. Install the EPDM close out seal (1111-9645) around the MAF Tube and clip into the edges of the upper air box tray.

13. Secure the MAF tube to the air box lid using the two (2) M8x25 bolts supplied (W500224). Torque to 20 Nm.

14. Orient the filter so it sits at a slight angle forward as shown.

15. Place the new ROUSH air box lid assembly (air box lid / filter / MAF tube) into the vehicle. If necessary, adjust the filter so it does not contact the bottom of the air box. Tighten the filter clamp.

16. Install the new clean air tube between the throttle body and the new ROUSH air box lid assembly. Secure the clamps for the air box lid and tighten both clamps on either end of the clean air tube.

17. Connect the brake aspirator hose onto the fitting in the clean air tube.

18. Connect the PCV line fitting onto the port in the clean air tube.

19. Re-connect the MAF wiring harness connector to the MAF sensor & push the lock into place.

Congratulations!!! You have completed the installation of the ROUSH Cold Air Kit. It is recommended that you save all parts removed from your vehicle during the installation of this kit.

All retail parts carry a 90-day warranty from the date of purchase. This warranty covers defects in materials or workmanship, and does not include (i) normal wear and tear, environmental conditions, improper installation; (ii) road hazards, misuse, abuse, neglect, accidents, collision, fire, theft, freezing, vandalism, riot, explosion, or objects striking the vehicle; (iii) misusing the vehicle, such as driving over curbs, overloading, racing, or using the vehicle as a stationary power source; (iv) altering, disassembling or modifying the parts; (v) defects caused or induced by failures, breakdowns, or damage by other parts, components or the vehicle; (vi) subjecting the parts to excessive moisture or water or any motor vehicle fluids (e.g.: oil, anti-freeze, battery acid, brake fluid, etc.); (vii) acts of God, natural disasters and other similar causes beyond the reasonable control of ROUSH; or (viii) application of chemicals that affect the parts. This Limited Warranty does not cover surface deterioration of paint, trim, and appearance items that result from use and/or exposure to the elements, such as stone chips, scratches, bird droppings, lightning, hail, windstorm, dings, dents, earthquake, road salt, tree sap, water or flood.

ROUSH SHALL NOT BE LIABLE TO REIMBURSE CUSTOMER/DEALER FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE INSTALLATION OR USE OF ANY PRODUCT SOLD THROUGH THIS CATALOG OR ARISING OUT OF ANY BREACH OF WARRANTY. EXCEPT AS MAY BE STATED IN THIS CATALOG, ROUSH DISCLAIMS ALL EXPRESS AND IMPLIED WARRANTIES, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL ROUSH’S LIABILITY EXCEED THE PRICE PAID BY CUSTOMER/DEALER FOR PRODUCTS SOLD REGARDLESS IF ROUSH HAS BEEN ADVISED IN ADVANCE OF ANY POTENTIAL PROBLEM OR IF A CLAIM IS BASED ON CONTRACT, TORT, STRICT LIABILITY, PRODUCT LIABILITY OR OTHERWISE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF IMPLIED WARRANTIES OR THEIR DURATION, OR LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSIONS OR LIMITATIONS MAY NOT APPLY.