Ford Flex 3.5L [#77-2578KS] Air Intake Installation

Ford Flex 3.5L [#77-2578KS] Air Intake Installation


This K&N air intake system is designed to
increase vehicle power and acceleration, by
reducing restriction in the intake path. The
77-2578KS intake kit fits 2010 Ford Flex with
3.5 liter engine, as well as additional vehicles
identified on the K&N website or catalog.
K&N power testing of this air intake showed
a gain of 9 horsepower at 4914RPM. With the
kit installed we ran the vehicle on the dyno
to test the sound comparison versus the stock
intake.
The kit includes components that have been
deigned or matched to the needs of the vehicle
to produce a safe horsepower increase. Detailed
installation instructions are included with
this kit. The tools needed for this install
are shown.
Turn the engine off and disconnect the vehicles
negative battery cable. Release the locking
tab and then disconnect the mass air sensor
electrical connection. Release the locking
tab and then disconnect crankcase vent tube
from the factory intake hose. Disconnect the
EVAP hose from the check valve. Loosen the
hose clamp that secures the factory intake
tube to the throttle body. Release the two
upper airbox latches. Disconnect the factory
intake tube from the throttle body, then remove
the upper airbox and intake tube from the
vehicle. Remove the fresh air duct cover from
the core support. Remove the two bolts that
secure the fresh air duct to the core support.
These bolts will be reused. Lift up the lower
airbox to dislodge it from the mounting grommets,
then remove the lower airbox and fresh air
duct from the vehicle. Remove the airbox mounting
grommets, from the airbox mounting bracket.
Install the K&N® filter adapter onto the
heat shield and secure with the provided hardware.
Install the provided edge trim onto the heat
shield. Install the provided rubber mounted
studs onto the airbox mounting bracket. Be
sure to install each rubber mounted stud with
two large fender washers and one rubber washer,
the fender washers should be on each side
of the bracket. Set the K&N® air filter into
the engine compartment. Set the heat shield
onto the rubber mounted studs and then secure
with the provided hardware. Install the K&N®
air filter onto the adapter and secure with
the provided hose clamp. Be sure to place
the large fender washers on top of the rubber
mounted studs so that they are between the
heat shield and rubber mounted studs. Install
one of the provided silicone hump hose onto
the throttle body and secure with the provided
hose clamp. The silicone hose is a tight fit
onto the throttle body.
Install the 90° vent fitting into the intake
tube. Install the remaining silicone hose
onto the intake tube and secure with the provided
hose clamp. Remove the two screws that secure
the mass air sensor to the factory airbox
and then remove the sensor from the airbox.
Install the mass air sensor into the intake
tube and secure with the provided hardware.
Remove the fresh air duct from the factory
airbox. The fresh air duct is tightly secured
to the airbox, once the locking tab is preyed
back the fresh air duct will dislodge from
the airbox. Install the fresh air duct into
the heat shield and secure it with the factory
screws in the original location, then reinstall
the cover onto the core support. Install the
intake tube into the silicone hose at the
throttle body and onto the filter adapter,
then secure with the provided hose clamps.
Connect the factory crankcase vent tube to
the intake tube. Attach the provided EVAP
hose onto the fitting on the intake tube and
then attach the open end to the EVAP check
valve. Reconnect the mass air sensor electrical
connection. Reconnect the vehicle’s negative
battery cable. Double check to make sure everything
is tight and properly positioned before starting
the vehicle.
It will be necessary for all K&N® high flow
intake systems to be checked periodically
for realignment, clearance and tightening
of all connections. Failure to follow the
above instructions or proper maintenance may
void warranty. This intake kit is not legal
for highway use in California or other states
adopting California emission standards. Check
our website for up to date information on
emissions legality for specific parts on specific
vehicles and for a list for the other CARB
adoption states. For more product information
go to knfilter.com
K&N makes products for nearly every vehicle
on the road. The K&N website allows you to
search products by vehicles or dimension,
download installation instructions, view dyno
charts showing typical horsepower gains for
this product, and view product details. For
more information on where to buy K&N products
go to knfilters.com

4 Replies to “Ford Flex 3.5L [#77-2578KS] Air Intake Installation”

Leave a Reply

Your email address will not be published. Required fields are marked *