INSTALLATION INSTRUCTIONS FOR ZETEC 2.0l ALUMINUM INTAKE KIT

 

The following instructions are a guide to help you install your new Intake. Some basic tools will be required to do this job; these are screwdrivers, a pair of pliers, vice grips (locking pliers) and a socket set.

 

CTA will not warrant any damage to the any pieces in the intake kit caused by improper installation.

 

First you will need to inspect that all the parts that came with the kit and that shipping did not damage anything, also this way you will become more familiar with the parts that you are about to install. To do this, you will not need an engineer’s degree, as long as you don’t rush the job and enjoy what you are doing.

Note the term, intake air temperature (IAT) sensor is going to be mention a few times. This is only regarding mid 99 and older vehicles.  From 99’s and up, the sensor is built in into the MAF.

 

Open main fuse box and remove fuses 4 and 11 (up to mid 99) or fuse 6 for late 99 and newer vehicles. The main fuse box is located beside the battery. This will reset the computer so that it will learn the new parameters after the installation is completed.

 

Unplug the MAF and the air temperature sensor electrical connectors as shown in Figure 1 (1998 Vehicle shown). Remove the IAT from the intake tube, if so equipped (Figure 1).

 

NOTE: The IAT is a screw in type 97 and older vehicles.

 

FIGURE 1

 

Remove the resonator and stock intake tube as shown in Figure 2A. If you have not already done so, remove the IAT from the intake tube, if so equipped (Figure 2B). For pre 98 vehicles, unscrew the IAT from the intake tube. Using a pair of vice grips (locking pliers), remove the intake resonator hold down studs (Figure 2A). These may be very tight and penetrating lubricant may need to be sprayed to assist in loosening the studs.

 

 

FIGURE 2A

 

FIGURE 2B

 

Remove fender boot as shown in Figure 3. You may choose to remove the remaining plastic fender inlet assembly.

 

FIGURE 3

 

All model year vehicles: Do not remove crankcase breather hose. Disconnect the end of the hose that was attached to the stock intake tube. (Figure 4)

 

FIGURE 4

Remove MAF from the stock air box by releasing holding clamps, if so equipped. (Figure 5)

 

FIGURE 5

 

Bend the supplied bracket to allow attachment of the hoop of the bracket to the MAF to Intake Tube gear clamp (Figure 6A and 6B). Bottom of support bracket must connect to the stock air filter box support using one of the stock bolts as shown.

 

FIGURE 6C

 

FIGURE 6D

 

Install throttle body elbow coupling using the supplied clamp. (Figure 7)

 

FIGURE 7

 

Install supplied air filter to the inlet side of the MAF. Please note the orientation of the MAF as it has a specific inlet and outlet. The filter may require some stretching to fit over the MAF. Please note that this

may be a bit difficult but will fit as shown in Figure 8.

 

FIGURE 8

 

Insert the IAT in the intake tube, if so equipped. Please note the proper positioning of the IAT as shown in Figure 9A. Apply a touch of grease to assist the IAT to slip into the intake grommet (Figure 9B).

 

Pre 98 vehicles (Not shown):  Carefully, using the correct size wrench, thread the IAT into the hole provided. View from inside the intake tube, that there is no gaps and that the orientation of the IAT is correct. The sensing tip should be in the air stream with the plastic supports in the vertical position.

 

 

FIGURE 9A

 

FIGURE 9B

 

Assemble the remaining portion of the intake kit.

1. Attach a coupling to the throttle body elbow then insert the main intake tube. Secure using the supplied clamps but do not completely tighten.

2. Attach the remaining coupling and then the MAF using the supplied clamps.

3. Attach the MAF to the previously installed MAF support bracket. The support bracket may need to be slightly bent to accommodate the fitment in your vehicle. Snug all connections. Do not tighten completely until proper fitment has been established.

4. All model year vehicles: Insert the silicone hose, provided with the kit, into the existing hose that was removed from the stock intake tube (Figure 4). Then cut hose to length, and insert other end onto the port on the new intake tube (Figure 10). Please use the zip ties provided, if necessary, to secure the ends of the new hose.

5. Once proper fitment has been established, secure and tighten all clamps and fasteners.

Do not over tighten clamps as this may tear the intake couplings.

 

FIGURE 10

 

Reinstall IAT and MAF electrical connectors.

 

FIGURE 11

  FINAL NOTES: 

  • Reinsert fuses 4 and 11 and close fuse box or fuse 6 (late 99 and newer models).

  • Check that all the tools are out of the way and make sure clearances are OK and that all fasteners are secured tightly.

  • Start up the car, wait a few seconds and rev the engine a few times.

  • Take the car for a spin.

  • It may take a couple of hours for the car’s computer to really learn the new flow and to adjust for better performance.

  • After a test drive, make sure every thing is secure.

  • If engine light occurs then it might be that the intake popped out of the throttle body and just need to reset the computer by removing the negative connection for 5 min.

Complete intake system installed.

 

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All material contained on this website is © Copyrighted 1999-2xxx. Contained material is property of CW Technical Services. and cannot be used or reproduced without written consent. Performance products are designed for competition use only and should never be used on public roads, unless so noted for such use. It is the consumers responsibility to check compliance with federal, state, and local laws before operating a modified vehicle on public roads. Performance parts manufactured or assembled by CW Technical Services are intended for competition use only and are not backed by any guarantees or warranties, and the user assumes all risks involved with installation and modification of their vehicle.