Volant Perfomance 19435 User manual

IMPORTANT WARRANTY & INSTALLATION
INSTRUCTIONS ATTACHED
Please Forward All Attached Information to Consumer
Warranty Not Valid Unless Returned to Volant Performance
Please be sure to review the enclosed instructions prior to beginning the installation process.
STOP

Closed Box Air Intake System
12-14 Ford F-150 3.5L
PN 19435/194356
INS194356
2
Please take time to read and understand these installation instructions.
Volant recommends that the installation of this system be performed by a qualified service center or professional
installer who has the necessary equipment, tools and experienced personnel. However, if you decide to perform this
install the use of an additional person may be required.
CAUTION: Never work on a hot engine bay. Allow time for the vehicle to cool.
Recommended Tools:
Flathead Screwdriver
Assorted Socket-Set
Ratchet
Ratchet Extension
Please confirm that all parts are present according to the bill of materials before beginning the installation.
Bill of Materials
1
Volant Plastic air box
4
¼ x 5/8 rubber washers
1
Pro5 or PowerCore® Filter
1
Coolant bottle
1
Volant Plastic air duct
4
¼ -20 x .50’ Truss head screw
4
#64 Clamps
1
3.5 to 3in reducer
1
MAF Adapter 6x4 ribbed
3
6mm –16 bolt
1
#56 Clamp
1
4.00 hump hose
1
Volant Aluminum air box lid
3
¼ lock washers
1
#48 Clamp
1
4.00 x 2.75 sleeve
1
Inspection window for aluminum lid
3
¼ x 3/4 washers
2
4mm x 16 Pan head screw
1
6mm x 25 bolt
1
Lid gasket
1
Coolant bottle fitting
1
Coolant bottle bracket
2
3/8 x 3/4 bolts
2
1/4 x 7/8 washers
2
3/8 x 1in washers
2
3/8 lock washers
1
6mm nut
1
Silicon o-ring

Closed Box Air Intake System
12-14 Ford F-150 3.5L
PN 19435/194356
INS194356
3
Installation Instructions:
Locate your vehicle’s battery and disconnect the negative battery cable,
this resets the computer and clears old air flow data to prevent CEL errors.
1. Using a 5/16 socket or nut driver loosen the clamp holding the factory air duct to the stock air box. (Fig A)
2. Using a 5/16 socket or nut driver loosen the clamps holding the factory air duct to the downpipes (Fig B)
3. Remove the air duct from the air box and downpipes by pulling straight off. Save in case vehicle needs to be
returned to stock. (Fig C)
4. Push out the red locking tab from the Mass Air Flow (MAF) harness then remove the harness from the sensor.
(Fig D)
5. Unclip the tabs holding the stock air box lid and remove the top of the stock air box. Save in case vehicle needs
to be returned to stock. (Fig E)
6. Remove the stock air filter. Save in case vehicle needs to be returned to stock. (Fig F)
7. Disconnect the hood sensor harness then remove bolt securing the sensor retention clip using a 10mm socket.
Save for re-installation. (Fig G)
8. Remove the 2 bolts holding the lower half of the stock air box in place. (Fig H)
9. Remove the 10mm bolt on the inner fender lip. Save for re-installation. (Fig I)
10. Lift up on the lower half of stock air box and coolant bottle. Position it so you can reach the three coolant lines
(Fig J)
WARNING: Over tightening hardware may alter the integrity of the Volant air intake system.
11. Install the stock bolt into the Volant coolant bottle mounting tray and hand tighten (Fig K)
12. Hand tighten the Volant tray onto the fender lip using the 10mm stock bolt from Step 9 . (Fig L)
13. Reinstall the hood sensor bracket in the stock location using the stock bolt from Step 7. (Fig M)
14. Route the hood sensor harness through the notch in the stock bracket and connect the harness to the sensor.
Tighten the tray using stock mounting bolts with hardware from Step 12. (Fig N)
15. Transfer the two small coolant lines onto the Volant bottle using the stock clamps. (Fig O)
16. Position the stock coolant bottle so the lower coolant hose can be removed without spilling the coolant. Remove
the C-clip holding the line in place. (Fig P)

Closed Box Air Intake System
12-14 Ford F-150 3.5L
PN 19435/194356
INS194356
4
17. Looking into the hose you can see a black O-ring under the white pressed in guide. (Fig Q1
18. Using a pick or small flathead screwdriver pry the stock O-ring out. Save in case vehicle needs to be returned to
stock. (Fig Q2)
19. Place the supplied O-ring into the factory position. Snap the line to the Volant bottle using the Factory C-clip.
(Fig Q3)
20. Transfer the coolant to the Volant bottle and seal with the stock cap. (Fig R)
21. Install the 3 ½” to 3” reducer to the passenger side down pipe with the #48 clamp using a socket of nut driver
ONLY. (Fig S)
22. Install the 4” sleeve onto the driver's side downpipe with a #64 clamp using a socket or nut driver ONLY. (Fig T)
23. Press the Volant box onto the factory rubber grommets. (Fig U)
24. Install the 4” hump hose onto the Volant box with a #64 clamp using a socket of nut driver ONLY. (Fig V)
25. Attach the coolant bottle tray to the Volant box using the 6mm bolt, 1/4 washers, 1/4 lock washer and 6mm nut.
(Fig W)
26. Install the Pro5 filter P/N 5119 onto the adapter and tighten with a 5/16”socket or nut driver ONLY. (Fig X1)
27. Install the Donaldson PowerCore filter P/N 61508 onto the adapter and tighten with a 5/16 socket or nut driver
ONLY. (Fig X2)
28. Remove the sensor from the factory air box and place into the Volant air duct. (Fig Y)
29. Tighten the sensor into place using the (supplied) 4mm screw. (Fig Z)
30. Press the Volant duct into the hump hose, reducer and sleeve. (Fig AA)
31. Plug in the factory sensor harness into the sensor. (Fig BB)
32. Tighten the #56 clamp onto the reducer with a 5/16”socket or nut driver ONLY. (Fig CC)
33. Tighten the #64 clamp onto the sleeve with a 5/16”socket or nut driver ONLY. (Fig DD)
34. Tighten the #64 clamp onto the hump hose with a 5/16”socket or nut driver ONLY. (Fig EE)
35. Attach the Volant lid onto the Volant air box using the (supplied) hardware (Fig FF)
36. Check all connections and reattach the battery cable. (Fig GG)
*Check that this air intake complies with your Federal, State and Local laws. We recommend saving your stock system.

Closed Box Air Intake System
12-14 Ford F-150 3.5L
PN 19435/194356
INS194356
5
BEFORE ROAD TESTING
1. Start engine, leaving the transmission in park and securing the parking brake.
2. Make sure to look and listen for any unusual noises or air leaks. Repair problems if needed.
3. Once completed it will be necessary to check periodically, after a few heat cycles, for realignment and tightening of all connections.
CARE AND CLEANING
Check the Pro-5 cotton reusable filter periodically and remove any excessive dirt build-up by tapping the filter on the ground and brushing off the
loosened dirt. Clean the filter by using a two stage cleaning kit to thoroughly clean and re-oil the filter. Re-oil every 10,000 miles without cleaning
to improve filtering in sand and dirt. Clean only when dirt is very excessive or 20,000 miles.
Installation Pictures
Fig. A
Fig. B
Fig. C
Fig. D
Fig. E
Fig. F

Closed Box Air Intake System
12-14 Ford F-150 3.5L
PN 19435/194356
INS194356
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CONTINUED ON NEXT PAGE
Fig. G
Fig. H
Fig. I
Fig. J
Fig. K
Fig. L

Closed Box Air Intake System
12-14 Ford F-150 3.5L
PN 19435/194356
INS194356
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CONTINUED ON NEXT PAGE
Fig. M
Fig. N
Fig. O
Fig. P
Fig. Q1
Fig. Q2

Closed Box Air Intake System
12-14 Ford F-150 3.5L
PN 19435/194356
INS194356
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Fig.
Fig. R
Fig. U
CONTINUED ON NEXT PAGE
Fig. S
Fig. Q3
Fig. U
Fig. S
Fig. T
Fig. V

Closed Box Air Intake System
12-14 Ford F-150 3.5L
PN 19435/194356
INS194356
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Fig. AA
CONTINUED ON NEXT PAGE
Fig. Y
Fig. W
Fig. X2
Fig. X1
Fig. Z
Fig. Y

Closed Box Air Intake System
12-14 Ford F-150 3.5L
PN 19435/194356
INS194356
10
Fig. BB
Fig.CC
Fig. DD
Fig. EE
Fig. FF
Fig. GG