Installing Zabteck True Cold Air Intake

Installing Zabteck Performance True Cold Air Intake By Jacob Dryer (JDBoxes) and Shaun T.

THE FOLLOWING INSTRUCTIONS ARE FOR BOTH KITS PLEASE READ THEM COMPLETELY!!

Required Tools: 8mm Socket

10mm Socket 3 ¾” Hole Saw (may have to purchase from specialty store) Drill Phillips Screwdriver Flathead Screwdriver Tape measure Hack Saw or Sawzall

Required Parts: Zabteck Performance True Cold Air Intake Kit Approximate Install time is 2 hours NOTE: This installation was shown on a Sport Trac that has the stock MAF and

the stock rubber intake hose. Your Sport Trac intake may be different but the

principal is the same.

PLEASE READ THE INSTRUCTIONS FULLY AND MAKE SURE YOU HAVE

ALL THE REQUIRED TOOLS AND ARE COMFORTABLE DRILLING INTO

YOUR TRUCK BEFORE INSTALLING THIS KIT.

PLEASE READ:

NOTE: 1

PLEASE DO NOT CUT THE FRONT TUBE. THIS IS THE TUBE THAT GOES FROM THE THROTTLE BODY TO THE

MAF. THE END OF THE PIPE HAS A SPECIAL KNURL IN IT TO HOLD THE MAF. THE COUPLER IS SLIGHTLY OFF IN

COLOR BECAUSE IT IS A SUPER STRONG COUPLER DESIGNED TO HOLD THE MAF AND THE PIPE TOGETHER

TO PREVENT THE INTAKE FROM SAGGING AND CAUSING PROBLEMS.

NOTE: 2

IF THIS KIT DOES NOT CONTAIN THE 4 HOLE MAF

ADAPTER. THIS IS BECAUSE YOU PURCHASED THIS FULL INTAKE KIT WITH THE UNIVERSAL C&L MAF KIT.

THIS KIT WILL WORK 100% WITH THE NON FLANGED MAF AND IT WILL EVEN MAKE INSTALLATION EASIER.

THANK YOU !!!! ZABTECK

Disconnect the MAF from the air box (4 - 10mm bolts, 2 on each side). If you have an aftermarket intake filter on your truck, remove the plate or adaptor, or any other brackets

mounted to the MAF housing. If you have a C&L MAF on your truck, remove any adaptors so just the hose end is showing.

MAC INTAKE AND FILTER AIR FILTER REMOVED

C&L MAF with aftermarket intake

If you have the stock air box, unclip the two clips holding the air box top on and

remove it along with the air filter. Remove the air box by pulling up so that the two marked rubber pieces pull out of their housing. (This will take some muscle)

Next, pull it toward the driver’s side to release the same type of rubber pieces from the fender wall.

Remove the fender guard from the passenger’s side wheel well. (5 Phillips head screws, and 4 - 8mm and 2 - 10mm bolts) This will come out as one large piece and takes some wiggling and bending (be careful not to crack it) to remove it completely from the truck. There may be a vacuum ball bolted to the fender well. Be careful not

to break the plastic lines that feed the ball.

Now looking at how your intake sits and everything lines up, make a straight line from the MAF to the fender. REMEMBER the intake doesn’t sit flat and points

DOWN toward the fender. The hole in your fender wall should be centered in the recessed part where the three holes are. NOTE: Every ST may be slightly different,

so make sure you are comfortable with this next step. If you drill the hole in the wrong spot you may need a filler plate to cover the damage.

(Zabteck sells these in Chrome for $20.00 shipped)

Here is the filler plate Paul used. He decided to carbon fiber his.

OK. Ready. Take a deep breath and make sure your location is correct. Drill the hole and install the grommet. Note the 2 positions below that will work. Be sure your hole is somewhere between the 3 shown, or your filter may not fit in the fender properly!!

Push the elbow though the grommet from inside the fender side of the truck and rotate it so the opening is pointing toward the rear of the truck with a slight upward angle.

DO NOT REMOVE THE FILTER FROM THE ELBOW. THIS PART COMES

ASSEMBLED FOR A REASON, AND IF YOU REMOVE THE FILTER THE

ASSEMBLY MAY NOT GO BACK TOGETHER CORRECTLY AND CAN

CAUSE PROBLEMS.

The elbow should look like this on the inside of the truck. Place the clamp over the elbow.

Now attach the 4 bolt flange to the stock MAF or attach the rubber coupling to the C&L MAF. The Zabteck kit comes with both adapters needed. Choose the correct one for your

truck. Attach the coupler to the MAF housing (4- 10mm) and make sure to line up the gasket. The rounded part goes toward the top. If using a C&L MAF remove the 4 bolt

adaptor and just use the rubber coupler and clamp.

Next you have to measure the length of the pipe you need to make the connection. Measure from the elbow to the MAF adaptor. PLEASE insure that you do NOT cut

the pipe too small. Measure it as many times as needed. REMEMBER the pipe has

to slide into the adaptors and be long enough for the clamps to grab the metal.

The best way to install the pipe is slide it all the way into the elbow or the MAF

coupling, then slide it into the other coupling. This will allow it to install

properly and not cause any damage to the other parts if you try to force it in.

Tighten the clamps once the intake tube is centered.

Note: The pictures below are from the installation of a Zabteck Full Under Hood Intake kit. The instructions apply to the Zabtek True CAI as well. The Black rubber coupling is not included in the

Zabteck kit. It can be found in a plumbing section of your local hardware store.

After cutting the appropriate length of pipe, slide about 3/4 of the rubber coupling onto the tube. Connect the other rubber coupling to the curved end of the tube, ensuring a connection which will allow you to adjust it into

the correct position and tighten later.

Slide the rubber coupling on to the MAF so that a secure connection is made between the tube and the MAF. Some people have found it easier to attach the rubber coupling to the MAF using techniques like heating the coupling

or by applying grease or soap. Tighten the clamps.

Connect the bent end of the tube to the throttle body and maneuver it into position. Secure the clamps and make sure the connection is air tight.

If you do not have Zabteck’s Intake Breather Bypass kit, connect the tubes and tighten the clamp.

Afterwards you should have something that looks like this.

IF you are going to do heavy off-roading or have a high water area we recommend

you purchase a filter wrap and install it with the filter.

Re-install the fender well and install all the bolts. Then tighten them to insure they all

realign themselves properly.

YOU ARE NOW COMPLETE!!!!!

Double check all your connections and make sure nothing was knocked loose or damaged during your install.

Start the truck. Let it idle for a good 5 min to learn the air flow. Take it for a ride and then double check everything again.

THANK YOU!!!

Basic questions can be answered at www.zabteck.com/faq.htm