AIRMAX

Installation Instructions

(1997-2001 Ford F-150 4.6 & 5.4L Part # 25400)

 

Important! Read all instructions before you begin installation.

 

1.      Remove throttle body cover. Loosen the clamps both at the throttle body and the air filter housing. Remove both crankcase hoses from the inlet tube. Unplug Air Temperature Sensor (ATS). Remove the original inlet tube from vehicle.

2.      Disconnect the Mass Air Flow sensor (MAF) plug from air cleaner housing. Unhasp the air cleaner housing to extract the MAF sensor. Disconnect the MAF wiring inside the canister. Push the wiring through to be used at a later step. Unbolt MAF from housing. Remove the rest of air cleaner housing from the engine compartment.

3.      Reassemble the MAF to the AIRMAX filter assembly. Using a new gasket and bolts provided. Be sure to locate the plug of the MAF to the bottom. Tighten to 10 ft/lb.

4.      Install AIRMAX filter housing to original placement. Install mounting hardware from bottom of grommets and through the housing assembly. Hardware is two 1.5”x1/4” bolts two 1/4” washers and two 1/4” nyloc nuts. Assemble finger tight for now.

5.      Install the AIRMAX air inlet pipe to throttle body, using the band clamp. The band clamp is to secure the tube to MAF housing.

6.      The rubber coupler from the band clamp is to seal the gap in between the air tube and throttle body. Once the gasket is set, tighten the clamp by tightening the two worm gear clamps on the band clamp. Tight enough so that the air tube does not slip in the gasket and the throttle body does not slip in the gasket. The same goes for the MAF to air inlet tube junction.

7.      Remove idle air bypass hose. Install with correct length hose supplied and attach this hose to the 3/4” nipple on inlet tube. Push the crankcase (PCV) hose onto the 5/8” nipple on air inlet tube.

8.      Install the rubber grommet into the air inlet tube. Install the ATS into the grommet. Reinstall the proper wire harness plug to ATS.

9.      Plug in the MAF to corresponding harness plug.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

	Parts List 1 AIRMAX Assembly 1 AIRMAX air inlet tube 1 K&N filter (RE-0920) 2 1.5”x1/4” bolts 4 3/4”x1/4” bolts 10 1/4” flat washers 6 1/4” nyloc nuts 1 3/4” black hose 2 Stainless steel band clamps 1 MAF gasket	Required Tools 10mm socket 5/16” socket 7/16” socket 7/16” wrench Flat tip screwdriver