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2005 Ford Expedition KN Filter Kits Installation

January 20th, 2010 · No Comments

1. Turn off the ignition and disconnect the negative battery cable.
2. Disconnect mass air sensor electrical connection.
3. Rotate crank case vent hose locking ring and pull crank case vent hose off of air filter housing. Un-hook wiring harness retaining clip from air box.
3a. Disconnect the brake booster vent line from the air filter housing as shown.
3b. Pull up on the heater control valve and wiring harness mounting clips to unhook them from the air box mounting studs as shown.
4. Remove the four air box mounting bolts shown with a 10mm socket.
5. Remove the intake tube mounting bolt shown
6. Remove the entire intake tube & filter assembly from vehicle.
NOTE: K&N Engineering, Inc., recommends that customers do not discard factory air intake.
7. On vehicles that are equipped with the intake tube support bracket, remove the two 13mm nuts securing the intake tube support bracket, remove the intake tube support bracket.
8. On vehicles that are equipped with the intake tube support bracket, reinstall one of the 13mm nuts removed in step #7 onto the lower mounting stud and tighten.
9. Disconnect TPS sensor electrical connection from throttle body.
10. Remove the four 10mm bolts retaining the throttle body to the intake manifold.
11. Lift throttle body from intake manifold. Then disconnect throttle body motor electrical connection.
NOTE: Take caution to avoid dropping debris down intake manifold throat.
12. Using the bolts removed in step #10, secure the throttle body to the K&Nо throttle body adapter with the gasket as shown.
13. Install the throttle body assembly onto the intake manifold with the hardware provided as shown.
14. Reconnect the throttle body motor and TPS electrical connections.
15. Install “L” bracket (#070026) onto the heatshield with the hardware provided as shown.
16. Install the edge trim onto the heatshield as shown.
NOTE: Some trimming of the edge trim may be necessary.
17. Install the provided nut inserts into the air box mounting holes as shown.
17a. Loosen the coolant recovery hose, hose clamps, and then remove the factory recovery hose shown. Be sure to catch any coolant, which flows out of the radiator during hose removal.
NOTE: Be sure to let the engine cool completely before removing the overflow hose or hot cool-ant will escape from the radiator and injury or damage may result.
17b. Install the supplied coolant recovery hose and secure with the provided hose clamps.
NOTE: Be sure to replace the coolant that was recovered during hose removal by replenishing it in the coolant recovery tank.
18. Install the heatshield as shown and secure with the provided hardware.
NOTE: Due to manufacture inconsistencies, some vehicles may not be equipped with threaded hole in the factory filter mounting plate. It will be necessary to drill a 1/8” hole in the air filter mounting plate and attach the heat shield bracket with the sheet metal screw provided.
19. Remove the two screws that secure the mass air sensor to the air box with the wrench provided, then remove the mass air sensor.
20. Install the provided gasket onto the K&Nо mass air adapter as shown. Sticky side down.

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