K27 Focus ST CCK Installation

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1 8967 Gilder Rd., Ste. A Houston, TX K27 Focus ST CCK Installation Important: On the allen drain plug that is included in the kit - We recommend using thread sealant tape on the threads of the drain plug to assure no small leaks in the can Drain Plug TQ: 120 in/lbs DO NOT OVERTIGHTEN. Drain intervals will depend on HP level and health of the engine. We recommend draining the can on your first oil change and determine the drain interval based on amount you find on your first drain. See end of guide for packing list and tools needed list. Step1 Disassemble of Engine Bay -Remove Engine Cover by pulling upwards swiftly on each corner (Yellow Circles Below) -Remove Rear Intake Pipe by loosing a hose clamp on each end and removing the 8mm securing it to the engine. (Yellow Arrows Below) Step2 Removal of Bumper -Remove Headlights by removing the 2 screws on each light and pulling them up/forward. Un plug and set aside. -Remove the 4 plastic clips on the upper bumper (black section by hood latch) and the 2 screws on each side. -Undo cable on hood latch and move aside -At the corner of the bumper near the wheel, remove the plastic clip holding the bumper up. As well as the clips along the side of the wheel liner. There will also be torx bolts on the edge of the bumper that need to be removed. -Under the car, remove the black skid plate clips, set aside the skid plate. -Unplug fog lights -The bumper is now ready to be removed by pushing the clips down that the head light was covering.

2

3 Step3 Removal of Intercooler Ducting/Shutter System Remove upper duct by unclipping on each side Remove lower duct by unclipping and rotating downward Remove Intercooler by removing x2 8mm bolts under the intercooler, loosing the coupler on each side and unplugging sensor. Unplug shutter actuator by plugging grey clip out from the plug then pushing downward Bring radiator core support down by loosing 2 10mm bolts on each side (just loosen do not remove) Remove driver's side of shutter system first by pulling it upward and unclipping. Then proceed to remove it from the passenger side. Install the intercooler back in, making sure to use the 2 bolts holding it, tightening the couplers and plugging the sensor back in. The shutter connector secure using small zip ties out of the way.

4 Step4 Catch Can Mounting -Insert the Nut Clips onto the bumper support as shown. Install drain plug or option drain kit into can. -Mount can onto bumper support using provided bolts. Install Filter. Step5 Removing Intake Manifold -Unplug MAP sensor and Fuel Rail Pressure Sensor (Passenger Side of IM) -Unplug Brake Booster Hose (Squeeze green parts to release) -Loosen coupler on throttle body -Remove Symposer Hose (now is a good time to install the Kozmic Symposer delete kit) -Remove the 5 10mm Bolts holding the intake manifold to the head -Move intake manifold back and remove the clips holding the knock sensor plugs (2)

5 -Remove the hose on intake manifold leading to PCV plate -Unplug throttle body by sliding the red part of the slip back then pressing down on it -Remove Intake Manifold from engine bay Step6 New Hose Installation -Remove OEM PCV Hose and cut the plastic hose to release the OEM Intake Manifold Connection -Using the 3/8 Plug Hose clamp it to the intake manifold fitting and install back on manifold -Install larger provided PCV valve into the plate on the engine. -Locate and remove the rear valve cover breather hose from the valve cover and intake -Remove the valve cover side fitting from the hose assembly and insert the provided plug and clamp -Insert the hose size adapter provided onto the valve cover side fitting as pictured below

6 -Install the valve cover side fitting onto the valve cover -Install the intake hose that you just plugged back into the intake. Make sure this hose sits ABOVE the valve cover fitting hose to ensure it does not rotate downward, as pictured.

7 Step7 Routing and Installation: Catch Can Hoses -The new PCV hose will be approx 40 long. Attach to new PCV fitting on engine with clamp. -Route hose as shown below to can, install the push-loc fitting into the end (no clamp) and attach to can -Cut Rear Valve Cover Line length to approx 60 (You may trim more later if too long) -Install this line into the size adapter fitting we just installed in the last step and follow the routing below. Note Zip Tie locations to keep it away from the belt and to clear the OEM engine cover. -Route this hose to the can, trim as needed and install the push-loc fitting into the end (no clamp) and attach to can

8 Step8 Assemble Car -Install Intake Manifold, Intake Pipe, Bumper and Engine Covers as removed. Intercooler air guides and shutters will stay removed from the car.

9 Packing List and Tools Required Hardware Included in the Kit: x4 Large Clamps x1 Small Clamp x1 3/8 Hose Plug Assembly x1 1/2 to 5/8 Hose Adapter Assembly x1 1/2 Hose Plug Barb x2 45deg 5/8 10an Push-Loc Hose Ends x1 Upgraded 5/8 PCV Valve x1 Large Inlet Can Breather Filter x1 3/8 NPT Allen Drain Plug x2 m6 nut clips x2 m6 bolts (10mm head) Assortment of Zip Ties ***Not Pictured Catch Can, 100 of 5/8 PCV Breather Hose*** Required Tool List: Flat Head Screwdriver 7mm Socket (For Charge Piping) 90 deg pick or something similar (PCV clip ring) 8mm Wrench T27 Torx Socket 10mm Socket with extension (prefer 6 +) 5/16 Allen Wrench or Socket (CCK Drain plug) Feel free to contact us via for any technical support or feedback on this kit Gilder Rd., Ste. A Houston, TX

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