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

Installation Instructions

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.

IMPORTANT SAFETY NOTICE

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.

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

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

4. Remove the clean air tube from the vehicle and transfer the clamps from
the take off component to your new ROUSH clean air tube (1162-9B659).

5. 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.

6. 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.

7. 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.

8. 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.

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

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

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

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

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

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

15. Install the new ROUSH clean air tube between the intake 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.

16. Re-connect the MAF wiring harness connector to the MAF sensor and 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.

WARRANTY

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.