I need some help. I attempted to install the FSWerks Cool-Flo Intake yesterday morning on my 2010 Sedan. Once I got everything taken off, I started the installation. The first problem I had was the MAF sensor housing was not big enough. It looked like is had some extra paint or slag in it, so I had to find something the file it out to make the hole bigger. Once I got that done, I attached the filter and tried sliding it into the car. In all the pictures I had seen, I never saw any lines below where the airbox sits. I think they are transmission cooler lines or something, but I managed to snake around them.
Now for the big problem. When I tried lining up the intake tube to the throttle body, is was extremely off center. I would have to bring the tube upwards and tilt it in an awkward position. To make it worse, the throttle body is smaller than the intake tube. The supplied silicone couplers are 3" in diameter, so it was too big for my 2.75" throttle body. I tried attaching the coupler to the throttle body as best I could then sliding the tube in and attaching that. I was trying to get it as tight as possible, then the hose clamp broke. After finding a thicker one somewhere, I resumed. The rubber mount that is screwed into the car for the intake to sit on is nowhere near the intake bracket. I had to pull the intake and mount towards each other then install the nut. I thought it looked ok and that it would work. The other problem I had was with the MAF sensor when trying to plug it in. It was extremely short, like more than anyone else had said. I finally got it to reach and plug in, but it looks stupid.
So after finally installing everything, I drove it down the road a couple times and everything seemed to be ok. The only thing I noticed was my car made a farting noise from the intake everytime I turned it off. When my girlfriend got home, we went to my cousin's cookout at his home about 45 minutes away. When I got there and pulled into the yard, I heard a whistling or sucking sound. I thought it sounded like air, so I checked it before I left. Turns out the coupler slipped off the throttle body and was sucking air in. I asked my cousin for a screwdriver and he held the tube over while I retightened the clamp. When I got done, we sat there and watched the tube slide right back off again because the mount was pulling it one direction and the coupler was too big to begin with. I made it to the auto store after cutting out at a red light one time and found a really thick hose clamp like the other one I had put on earlier. I tightened it up pretty good and I made it home without anymore problems.
Has anyone else had this kind of problem and how did you fix it? I think that if I find a 2.75" to 3" adapter hose it will fix that problem. Then if I drill a new hole for the mount to sit in, it will fix the alignment issue. Does that sound about right?
You can see how far away the mount is and how far stretched the MAF Sensor is.
Different angle of how far away the mount is from the bracket. I ended up unscrewing it some to give me a little more leverage.
How I ended up fixing the coupler. These clamps are considerably stronger than the flimsy ones FSWerks sent.
I forced my intake in to the spot that is suppose to hold it in....I also Wrapped the MAF sensor around the front of the intake. Because the other way (which is the way you have it) Seemed like it would break it.
I initially had it going in front of the intake but it seemed like there was more pressure on it, so I put it behind it. That reduced the pressure by a tiny bit but not much. Did you have problems with the coupler at the throttle body? I just ordered a Samco reducer and a matching coupler for the bottom since they come in blue, so hopefully that will work out. I'm going to go check the intake later beause it will come off whenerver it feels like it, but it stayed in the same place the whole ride home last night (about 15 miles). I really do like it though, sounds nice on the car.
I just went and looked at it again. The intake is still on like it was last night. I also tried connecting the MAF sensor around the front and it is extremely tight. I posted something on FSWerks facebook page and they said the intake probably wasn't installed correctly. I mean, it ain't sticking out my roof. The problem is all the variances between different model years, plain and simple.
I didn't have problems with the couplers at all. I pretty much had plenty to choose from and tightened them until I couldn't tighten them anymore....Overall I like it. The only problem I had was the damn rubber thing on the bottom where the 2nd hose goes.
I mean like from 03-11. There are different air box setups and they are all attached differently. In the directions they say you have to take something off from underneath the car. I did take off the cover thing but I really didn't need to because I would have been able to remove the stock intake from the top.
I think all I need is the reducer and I will be fine. It looks to be holding the way it is but I will find out when I drive the car this week. The reducer will make the fit even tighter and the clamp should seal it up.
You shouldn't need the reducer. Unless you have been a major accident physically altering the front sub-frame, you should be able to the the CAI positioned correctly. I would loosen all the clamps and re position it the correct way. It WILL fit the way it is supposed to without any modifications. Like i said before SOMETHING is off on the alignment.
For the MAF, pull some more of the wire loom off the wires. The wires are tapped together. Unwrap the tape and it will give you some more slack. If you want to keep the stock look, go to Advance or Auto Zone and get some more loom. You can use it to cover the wires you uncovered during the install. As for the coupler and the actual intake tube alignment, I would send those pics to Vik at FSW and have him take a look at them.
I was actually looking at some wire loom last night to buy in a different color because I knew how it ended up looking. Maybe I will find some and then completely unwrap the whole and get everything right and put new loom on it. I posted this problem on FSWerks facebook and they said to call Vik also. I think I am ok right now, I just need to give the MAF more room and I will be good. Everytime I look at it I don't have much time and I usually don't get anything done, but I will make sure I get it taken care of as soon as possible.
I just installed one on mine wednesday and i had the same issues you did.
The seal around the maf seems larger then the hole, i might have a vac leak now. I had to pull the fender shield out just to get the filter on after i slid the pipe down into position. Las was the fitment of the intake to the throttle body. I think i had to clamp mine down to the smaller tube size.
I think the problem there is the intake is for "2.0 and 2.3" duratecs maybe the 2.3 duratec has a larger throttle body?
I had another issues you didnt mention. The breather line for the engine block. The stock setup had a plastic line from the back side of the valve cover around to the flexable boot connecting to the airbox. This intake just has a little section of hose.
My hope was to get rid of that setup all together. Using a seperate engine filter or a better line or something other then that plastic pre shaped line
I guess now days you cant expect much for $200. [???]
It says in the instructions that the MAF won't fit like stock, but to tighten it until the seal is compressed. You are also supposed to assemble the intake with the filter before positioning it in place. As for the plastic line, I didn't think it would work out too good being stuck in the little piece of hose but it seems to be the least of my concerns.
The couplers seem to be staying in place since I put the larger clamps on but I am still going to use the Samco couplers to get an even better fit. I check it everytime I get done driving and they don't seem to be moving at all.
I know of over 30 people personally with 2010 or 2011 cars using the fswerks intake and none of them had those problems. There may have been an error while they were being made but I doubt it. Just call vik and email him detailed pics.
Not a stupid question because I actually did think that at one point. I checked the invoice and the driections and they both said 2.0 & 2.3 Duratec All. I have never really seen a Zetec engine bay or have really paid attention to the intake location if I have seen one, so I wouldn't even be able to tell if the mispackaged it. Everything seems to be in the right place, so I just assumed it was my car or installer (me) error.
lol i dont drive like a granda at all lol. it dropped down a bit when i couldn't keep my foot off the pedal cause this intake sounds so awesome haha. but even going about 75mph at a constant speed it still was reading 48mpg man. i dunno why it is getting such good mileage. i have only added the intake so far. i run synthetic oil and put premium gas in it.(92-93 octane). No Tune should help when i get the tune from fswerks in the next few weeks or so.
It roughly calculates it using inputs such as throttle position, engine load, rpm, injector on time, etc etc. Its not terribly accurate but it does ok.
just figured up the actual numbers based on trip meter and gallons at fill up. 432 miles on 11 gallons. 39.27mpg its not 50 but its still doin quite well
Usually it goes sky high when you fill up and get right on the highway, mine read 47.5 mpg one time. Did you happen to take any pictures of the mounting bracket before you attached it to the rubber mount, like just sitting there? Any slipping of the coupler on the throttle body?
What exactly is it you wanted a pic of? And no I've had no slipping at all. Fits very securely. The mounting bracket where it attached to the body of the car is meant to give a little due to the engine twirking when started or jolted. But at the throttle body and down to that bracket it is very sturdy and solid.
Mine slipped off also. I ran a log and Tom told me i had a leak. I didnt check it because it was on so solid. I thought it was another hose that may of been leaking a little.
I poped the hood and sure enough the intake slipped off the Throttle body just like that other guy. I also bought a new hose clamp that has a different design.
I think since im not the only one with this issue i might try and fine a different coupler that has a slight taper.
The couplers are kinda greasy or somthing. The rubber has a greasy kinda feel to them. Maybe i should try cleaning it up with somthing sticky so it sticks a little better.
Its not a problem with the install its pretty easy to do. Maybe some of the parts or the way its built has changed a little?
The couplers are silicone, that is why they feel slippery. I ordered a reducer from Samco to put on the throttle body but it has to be made to order by them in the UK so I won't get it until the end of July.
I haven't had any problems like you've said you've been having, and I've had my intake on for roughly 40k miles now. It does angle a little bit towards the front of the car, it's not supposed to just go straight up and down. Also as you can see in this pic my coupler isn't pinched like yours. Are the couplers any different and maybe you have the one for the intake to TB where the intake meets the filter ?
I haven't had any problems like you've said you've been having, and I've had my intake on for roughly 40k miles now. It does angle a little bit towards the front of the car, it's not supposed to just go straight up and down. Also as you can see in this pic my coupler isn't pinched like yours. Are the couplers any different and maybe you have the one for the intake to TB where the intake meets the filter ?
ok mileage update. hand calculated it was 48.2 so the cars calculator is within 1mpg +-. Also i think your coupler was bent over because you didnt have the tb and the intake tube fully inserted equally on both sides. the coupler is only supposed to hold them together not support the intake. did you put the spacer on the wheel well in the correct location? this could be your issue.
I just bought my FSwerks intake as well and came across a similar issue. When I attempted to put the coupler to into the throttle body it was very loose. I could tell that even though you would tighten the clamp you would not get a good seal. Its a good thing I had an extra reducing coupler around. I love the overall fit, finish and quality of the product. FSwerks should have included a better fitting silicone coupler for the throttle body.
There are actually two main reasons we use the straight 3" silicone hose rather than a reducing silicone hose.
1. Many of our customers use an aftermarket throttle body which is always 3" in diameter. So our 3" silicone will fit perfectly with that setup as well as allow proper fitment with the OEM 2.75" throttle body. Silicone hose in general is designed to allow flexibility so it will seal properly when properly installed.
2. Reducing silicone hoses are much more expensive than straight silicone hose and to maintain our low selling price of $199.95 we chose to use a more affordable and multi purpose fitting hose.
48.7 miles to the gallon? Are you even stepping on the gas? LoL
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