How to: Install a K&N CAI in a V6

asull85 · February 15, 2012

How to install a K&N Cold Air Intake (57-2564) in a 4th Gen 4.0L V6 Explorer

Tools Needed:
Flathead screwdriver
Rachet
10mm socket
7(?)mm socket
Drill
5/32” drillbit
½” metal screws (2)

I don’t have any photos of the stock air box as I had removed it for the KKM intake…

Begin by disconnecting the negative terminal on your battery.
After that carefully unplug your MAF and remove it from the air box lid.
Set aside in a clean, dry area.

Loosen the clamps securing the air box to the hose and from the hose to the throttle body using a flathead screwdriver.

Remove air box lid and remove the filter

Carefully remove the bottom of the air box. I found it easiest to apply pressure to the air box wall closest to the engine until the two inserts (can’t think of the actual name) release from the quarter panel.
From there gently lift up on the air box until it pops out.

Disconnect the vacuum hose from the intake tube

Remove the intake tube

Attach the silicone hose to the K&N intake tube and attach to the throttle body.

Place heat shield in the engine compartment but do not secure it yet. In order to do so, you will need to drill two holes in the inner fender for two metal screws.

Attach K&N filter to the intake tube using using the 3.5” to 3” coupler

Attach the MAF to the intake tube. Make sure to install it in the proper direction.

Attach the vacuum hose to the intake tube.
*NOTE* I removed the factory vacuum hose and used the hose that came with the kit. Trimming of the hose will be needed. I recommend you trip ¼” at a time until there are no binds or kinks in the hose.

Secure the heat shield. Tighten all clamps. Reconnect the battery and start the truck. Check for leaks and trouble codes.

Enjoy!
*NOTE* A support bracket is included in the kit, however I could not find a pre-drilled hole to attach it to. I’m currently using a clamp from the heat shield to support the filter and intake tube to prevent vibration. See photo

rusty813 · February 17, 2012

thanks for the nice write up can you tell any difference in power after they install cause my car is a v6 as well and interested in doing this upgrade

asull85 · February 18, 2012

I definitely had some more power with the new intake. Once I installed a custom tune the difference was unreal.

jg101987 · April 28, 2012

Nice write up. I have the same truck (in black pearl slate though). Done a few mods, but nothing to the engine yet. Been thinking about a CAI, and I always like pictures before I start ripping things apart

Your registry page says you removed the K&N CAI though, is this the same one you're installing here? If so, any particular reason?

asull85 · April 28, 2012

jg101987 said:
Nice write up. I have the same truck (in black pearl slate though). Done a few mods, but nothing to the engine yet. Been thinking about a CAI, and I always like pictures before I start ripping things apart

Your registry page says you removed the K&N CAI though, is this the same one you're installing here? If so, any particular reason?

I had a KKM "CAI" installed before I got the K&N one. I wasn't too crazy about it.

jg101987 · April 28, 2012

asull85 said:
I had a KKM "CAI" installed before I got the K&N one. I wasn't too crazy about it.

My mistake, I misread it. That's what I get for trying to read all that small text on my phone

Nonetheless, I think you've inspired me to do it. You said the power was unreal after the tune, what about mpgs? Any significant difference? And can you explain a little more about the tuning (I'm still kinda new to this).

OffTrac · April 28, 2012

the difference was unreal.

I believe this statement.

east1la · May 11, 2012

How much was the kit? Where did you get the the custom tune?? I'm thinking of doing this.

asull85 · May 11, 2012

I got it for about $215 from Amazon. The tune is from Henson Performance.

barrettwoods23 · July 6, 2012

i was wondering if this is a perfect fit the part # for the knn kit is for a v8 o6 explorer not a 06 v6 explorer thanks

swshawaii · July 6, 2012

K&N's 57-2564 was designed to fit 2004 and 2005 Ford Explorers with the 4.6 liter engine and gains 10.4 horsepower @ 4921 rpm.

Also note the stock intake produced more HP and torque up to 3200 RPM on the 4.6L V-8.
http://www.knfilters.com/dynocharts/57-2564_dyno.pdf

banditxp · July 7, 2012

swshawaii said:
Also note the stock intake produced more HP and torque up to 3200 RPM on the 4.6L V-8.
http://www.knfilters.com/dynocharts/57-2564_dyno.pdf

thats the 2V 4.6L

check out the 3V one
http://www.knfilters.com/dynocharts/57-2573_dyno.pdf

I put the K&N system on mine and i left a good difference and then when i did the 3" exhaust... wow woke right up.

FYI, instakk sheet from KN for V8: http://www.knfilters.com/instructions/57-2573_inst.pdf

howell · July 9, 2012

As soon, as I can afford the set up Ill be joining you fellows! Thanks for the write up.

ctgblue · July 20, 2012

I cannot even find a COI by any mfr, designed for the 2010 with the 4.0L
Much less a cutom tune.

Are you using one for another year and engine? Because that part number shows up as for a 2003-04 Mercury Marauder, 04 Explorer with 4.6L V8, etc..

asull85 · July 21, 2012

ctgblue said:
I cannot even find a COI by any mfr, designed for the 2010 with the 4.0L
Much less a cutom tune.

Are you using one for another year and engine? Because that part number shows up as for a 2003-04 Mercury Marauder, 04 Explorer with 4.6L V8, etc..

Its for an 04 Explorer 4.6L, it fits perfectly. The custom tune I use was made specifically for my truck.

howell · August 5, 2012

I didnt see if this was in the post... I may have missed it.

Did the stock maf sensor fit the new intake? direct bolt on right?

downwithmilton · August 6, 2012

howell said:
I didnt see if this was in the post... I may have missed it.

Did the stock maf sensor fit the new intake? direct bolt on right?

Yes the stock MAF sensor fits right in.

howell · August 6, 2012

thanks for the reply to my question.

malamorian · May 22, 2013

I installed this same intake into a 2010 ford explorer xlt 4.0l with a throttle body spacer.you can not use the heat shield but I used the mount that came with the intake by flipping it around and drilling the bolt hole out so I can mount it to the first alternator bolt .

ryan730 · November 18, 2013

Do you have the link to the tune you used? Could you do a thread on how you customized that?

How to: Install a K&N CAI in a V6

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