Grille Removal F150

1. Park your truck in a flat level area.  Under most conditions you have enough clearance to do this with the car on the ground, however having access to a lift can make some parts slightly easier.
   
   
2. Using your trim tool, remove the two clips holding the inlet snorkel in place
   
   
   
   
3. Remove the other seven clips holding the upper grill/radiator cover in place.
   
   
   
   
   
4. Some trucks will have two more trim clips in the corners near the core support.
   
   
   
   
   
   
   
5. In the front corner of the wheelwell of the front two wheels you'll find two small 7mm bolts on the passenger's side, and either one or two on the driver's side.  Remove them using your 7mm wrench.
   
   
   
   
   
   
   
   
   
6. Gently pry outward on the fender flare and pop the clips free with your trim tool, making sure not to scratch the paint in the process (laying down painters tape on top of the paint can prevent minor scratches. (If not equipped with the fender flares skip this step.
   
   
   
   
   
   
   
7. With both corners free firmly pull outward on the under-grille trim to remove it from the car.  Set it somewhere safe.
   
   
   
   
   
   
   
8. With the trim removed, use your 8mm to remove the 8mm bolts found on the lower right corner of each side underneath the headlight.
   
   
   
       
   
   
   
9. Unplug the grille shutters, and the accessory wiring plugs found next to the hood latch.
   
   
   
   
   
10. Use your trim tool to pop the wiring harness free.
    
    
    
    
    
11. Remove the 4 8mm bolts holding the top part of the grille shell in place.
    
    
    
    
    
12. Slowly pull outwards on the entire grille assembly to remove it from the car.  Set it somewhere safe for now.
    
    
    
    

Grille Removal Raptor

1. Park your truck in a flat level area.  Under most conditions you have enough clearance to do this with the car on the ground, however having access to a lift can make some parts slightly easier.
   
   
2. Using your trim tool, remove the two clips holding the inlet snorkel in place
   
   
   
   
   
   
   
3. Pull out the remaining seven clips holding the upper grille/radiator cover in place and remove it from the car, you'll probably need to lift up the snorkel gently to pull it free.
   
   
   
   
   
4. Remove the one clip on either side of the car holding the top of the headlight bezel in place.
   
   
   
   
   
5. Pop the headlight bezel free where it meets the center piece of the bumper.  Gently pull outward on the top of the headlight bezel and pop it free of the clips.  You should be able to leave it attached on the outside as completely removing them isn't needed.
   
   
   
   
   
   
   
   
   
6. Remove the three clips on either side holding the rubber radiator shroud in place on the grille shroud.
   
       
   
   
   
7. You can leave the clips holding it to the core support.
   
   

8. Remove the four 10mm bolts on the top of the grille using your socket.

   These bolts, like many others go straight into metal (some into plastic).  Make sure to avoid torquing these bolts too hard either when loosening or tightening these bolts as it's very easy to strip them out on accident.

   
   
   
   
   
   
   

9. Undo the two electrical plugs on the top center of the grille structure by depressing the clip then pulling them out.
   
   
   
   
   
   
   
10. Gently spread the retainer ring on the washer line and unplug the hose.
    
    
    
    
    
    
    
11. Using your trim tool again, remove the two clips holding the harnesses to the support.
    
    
    
    
    
    
    
12. Undo the two 8mm bolts on each lower corner of the grille using your extension and an 8mm socket.
    
    
    
    
    

13. Remove the front grille assembly and set it somewhere safe!
    
    
    

Grille Removal 

1. Park your truck in a flat level area.  Under most conditions you have enough clearance to do this with the car on the ground, however having access to a lift can make some parts slightly easier.
   
   
2. Using your trim tool, remove the two clips holding the inlet snorkel in place
   
   
   
   
3. Remove the other seven clips holding the upper grill/radiator cover in place.
   
   
   
   
   
4. Some trucks will have two more trim clips in the corners near the core support.
   
   
   
   
   
   
   
5. In the front corner of the wheelwell of the front two wheels you'll find two small 7mm bolts on the passenger's side, and either one or two on the driver's side.  Remove them using your 7mm wrench.
   
   
   
   
   
   
   
   
   
6. Gently pry outward on the fender flare and pop the clips free with your trim tool, making sure not to scratch the paint in the process (laying down painters tape on top of the paint can prevent minor scratches. (If not equipped with the fender flares skip this step.
   
   
   
   
   
7. Disconnect the wiring for the corner lights.
   

   
   
   
   
   

   
   
   
8. With both corners free firmly pull outward on the under-grille trim to remove it from the car.  Set it somewhere safe.
   
   
   
   
   
   
   
   
   
9. With the trim removed, use your 8mm to remove the 8mm bolts found on the lower right corner of each side underneath the headlight.
   
       
   
   
   
10. Unplug the grille shutters, and the accessory wiring plugs found next to the hood latch.
    
    
    
    
    
11. Use your trim tool to pop the wiring harness free.
    
    
    
    
    
12. Remove the 4 8mm bolts holding the top part of the grille shell in place.
    
    
    
    
    
13. Push the rubber trim on the bumper down and slowly pull outwards on the entire grille assembly to remove it from the car.  Set it somewhere safe for now.
    
    
    
    
    
    
    
14. Gently rotate the bracket for the transmission cooler line.  This should bring the line in towards the radiator/AC condensor and give a little more space to fit the intercooler without rubbing.
    
    

F150 & 2021+ Raptor Intercooler Installation

1. Mark the radiator flap along the seam and then the outer side of the outermost nubs that stick out.
   
   
   
   
   
2. Cut the front edge of the radiator shroud flap .  Starting on the outside edge of the outer most nubs then along the crease all the way across.  You may be able to trim less depending on your specific vehicle as there are some differences in vehicle tolerances that we've seen.
   
   
   
   
   
   
   
   
   
   
3. Remove the two 10mm bolts on the hood bracket, mark above to keep latch aligned
   
   
   
   
   
   
   
   
   
4. Unloop the cable ferroule from the cable bracket.
   
   
   
   
   
   
   
5. Squeeze the plastic cable retainer and remove cable
   
   
   
   
   
6. Set the latch up on the radiator support and out of the way.
   
   
7. Install the lower intercooler bracket to make sure you trimmed enough for it to not hit the bracket or be in the way of the rubber holes.
   
   
   
   
   
8. Remove the rubber bumpers from the stock intercooler and add them onto the new COBB unit
   
   
   
   
   
   
   
   
   
9. Install intercooler and wiggle to get the rubber mounts in place correctly.
   
   
   
   
   
   
   
10. Pass your cable through the upper intercooler bracket.
    
    
    
    
11. Reinstall the cable onto the latch assembly.
    
    
    
    
    
    
12. Install the top mount bracket onto the intercooler mounts.  Using the stock bolts do your best to line up the hood latch while pushing down on the bracket to keep it as low as possible.
    
    
    
    
    
    
13. Remove your BPV from the intercooler core using an 8mm socket.  Turn the BPV counter clockwise until it stops and then pull upward gently to remove.
    
    
    
    
    
14. After checking to make sure the o-ring isn't torn.  Lubricate the o-ring with super lube then Install the bpv by holding it at the shown angle and gently wiggling until it slides in, then turn clockwise until it stops
    
        
    
    
    
    
    
15. Using two washers, a lock nut and the longest bolt, attach the BPV to the bpv tube.  Make sure the pbv is clocked all the way to the right (without forcing it) before tightening down hand tight with your wrenches (do not overtighten or the plastic will crack)
    
    
    
    
    
    
    
    
16. Insert plastic caps into the lower and upper grille shutter connectors.
    
    
    
    
    
17. Cut out connectors from BPV hose carefully.   Cutting a v shape allows a bit more space to relieve pressure on the fitting so you can pull it out properly.Optionally using a heat gun to loosen the plastic and then pulling out the connectors can work as well.
    
    
    
    
    
    
    
    
    
    
18. Remove the o-rings from the inside of the connector.
    
    
    
    
19. Lube up and install the new o-ring as well as the ones on the rear of the connector.
    
    
    
    
    
    
    
    
    
20. Add two of the smaller clamps to each end of the bpv tube.
    
    
    
    
21. Install them into the tubes.  Make certain the o-ring doesn't get pushed out as you install it into the hose.
    
    
    
    

22. Reinstall onto the turbo inlet tube
    
    
    
    

    Make sure not to kink the hose as it may cause issues.  Sometimes you can remove the kink by slightly changing the routing of the hose, or in some cases you may need to remove a small amount of material from the straight end.
    
    
    

    
    
    
23. add 2 48 clamps to the 45 degree coupler and pre-install it on the intercooler end.
    
    
    
    
24. On the opposite end of the bypass valve tube you'll install one of the two expanding couplers.  Add a #48 clamp to the smaller end and attach that put that over the end of the bypass valve tube.  The other larger end can get a #56 clamp.
    
    For 2019-2020 you'll use the shorter coupler, for 2021+ vehicles you'll use the long one.  The long end with the COBB logo is the smaller diameter end.
    
    
    
    
    
    
    
    
    
    
    
    
    
    
25. Add 2 44 and one 48 clamp to the y- coupler
    
    
    
    
    
26. Install onto the Intercooler and the two turbo inlet pipes
    
    
    
    
    
    
27. Connect the bpv tube to the bpv
    
    
    
    
    
28. Reconnect the BPV harness.
    
    

2017-2020 Raptor Intercooler Installation

1. Loosely Install intercooler bracket using stock hardware with bumper support brackets.  Make sure the tab end is pointing up.  If you're running an aftermarket or frame-cut bumper you may not need these.
   
   

   The bumper support brackets are not needed on F150 installations.

   
   
       
   
   
   

2. Using a shorter bolt, lock nut, and a washer on each side attach the bumper support loosely.
   
   
   
   
   
   
   
   
   
3. Tighten the bumper support bolts down to stock torque specs
   
   
4. Torque down the intercooler bracket.
   
   
5. Fold down the bottom rubber mat with clips.
   
   
   
   
   
6. Pressing down on the top, go up from underneath to mark out a circle.
   
   
   
   
   
   
   
7. Cut out the circle carefully using a razorblade or sharp scissors.  May need to cut on the outside of the drawn line to make things fit properly.
   
   
   
   
   
8. From one inch behind the center of your hole, measure 7.25:" towards the closest side of the car then leave a mark.
   
       
   
   
   
9. Make a 4" circle around that hole to mark the cut
   
   
   
   
   
   
   
   
   
10. Cut and repeat on the other side.
    
    
    
    
    
11. Remove the two 10mm bolts on the hood bracket, mark above to keep latch aligned
    
    
    
    
    
    
    
    
    
12. Unloop the cable ferroule from the cable bracket.
    
    
    
    
    
    
    
13. Squeeze the plastic cable retainer and remove cable
    
    
    
    
    
14. Set the latch up on the radiator support and out of the way.
    
    
15. Remove the rubber bumpers from the stock intercooler and add them onto the new COBB unit
    
    
    
    
    
    
    
    
    
16. Install intercooler and wiggle to get the rubber mounts in place correctly.
    
     
    
    
    
    
    
17. Pass your cable through the upper intercooler bracket.
    
    
    
    
18. Reinstall the cable onto the latch assembly.
    
    
    
    
    
    
19. Install the top mount bracket onto the intercooler mounts.  Using the stock bolts do your best to line up the hood latch while pushing down on the bracket to keep it as low as possible.
    
    
    
    
    
20. Check clearance with transmission cooler line.  If it looks like it will touch adjust this bracket using a pair of channel locks or a crescent wrench.  Bending it across more towards the driver's side.
    
    
    
    
    
    
    
    
21. Double-check clearance with the stock transmission cooler.  If the lip sticking out is too close you may want to trim it down.
    
    
    
    
    
    
    
22. Remove your BPV from the intercooler core using an 8mm socket.  Turn the BPV counter clockwise until it stops and then pull upward gently to remove.
    
    
    
    
    
23. After checking to make sure the o-ring isn't torn.  Lubricate the o-ring with super lube then Install the bpv by holding it at the shown angle and gently wiggling until it slides in, then turn clockwise until it stops
    
        
    
    
    
    
    
24. Using two washers, a lock nut and the longest bolt, attach the BPV to the bpv tube.  Make sure the pbv is clocked all the way to the right (without forcing it) before tightening down hand tight with your wrenches (do not overtighten or the plastic will crack)
    
    
    
    
    
    
    
25. insert the terminal plugs into the provided connector
    
    
    
    
    
    
    
    
    
26. Install your connector into the stock fan connector and move up the red connector to lock it in place.
    
    
    
    
    
    
    
27. Ziptie the connector out of the way on the frame away from any heat sources.
    
    
    
    
    
28. Insert plastic caps into the lower and upper grille shutter connectors.
    
    
    
    
    
29. Cut out connectors from BPV hose carefully.   Cutting a v shape allows a bit more space to relieve pressure on the fitting so you can pull it out properly. Optionally using a heat gun to loosen the plastic and then pulling out the connectors can work as well.
    
    
    
    
    
    
    
    
    
    
30. Remove the o-rings from the inside of the connector.
    
    
    
    
31. Lube up and install the new o-ring as well as the ones on the rear of the connector.
    
    
    
    
    
    
    
    
    
32. Add two of the smaller clamps to each end of the bpv tube.
    
    
    
    
33. Install them into the tubes.  Make certain the o-ring doesn't get pushed out as you install it into the hose.
    
    
    
    

34. Reinstall onto the turbo inlet tube
    
    
    
    

    Make sure not to kink the hose as it may cause issues.  Sometimes you can remove the kink by slightly changing the routing of the hose, or in some cases you may need to remove a small amount of material from the straight end.
    
    

35. add 2 48 clamps to the 45 degree coupler and pre-install it on the intercooler end.
    
    
    
    
    
36. On the opposite end of the bypass valve tube you'll install one of the two expanding couplers.  Add a #48 clamp to the smaller end and attach that put that over the end of the bypass valve tube.  The other larger end can get a #56 clamp.
    
    For 2019-2020 you'll use the shorter coupler, for 2021+ vehicles you'll use the long one.  The long end with the COBB logo is the smaller diameter end.
    
    
    
    
    
    
    
    
    
    
    
    
    
37. Add 2 44 and one 48 clamp to the y- coupler
    
    
    
    
    
38. Install onto the Intercooler and the two turbo inlet pipes
    
    
    
    
    
    
39. Connect the bpv tube to the bpv
    
    
    
    
    
40. Reconnect the BPV harness.
    
    
    
    

1. Remove ambient air temperature sensor from grille by gently popping it out and unplugging the harness. 

   2018 only, later year vehicles will have the ambient air temperature sensor in a different position where it is not required to be moved.

   
   
   
   
   
   
   
   
   

2. Pop out the grille shutters one by one with a pry tool.
   
   
   
   
   
   
   
   
   
3. Remove the motor by pulling sideways on the flat end of the retaining clip by prying the clip away from the support.
   
   
   
   
   
   
   
   
   
4. Trim out the top edge along the line marked.
   
   
   
   
   
   
   
5. Remove the rubber piece from the bottom of the grille assembly by removing all of the clips with your trim tool.
   
   
   
   
   
6. Cut inward along the inside edge of the grille clips the furthest to the outside.
   
   
   
   
   
   
   
   
   
7. Now cut out the inside along the line you marked earlier.all the way through the lighter piece of plastic but not into the grille itself.  Sometimes it can be easier if you do it in stages to make the cuts straight.  Once done you can pop the center three metal clips free and remove the center portion of the grille surround.
   
   
   
   
   
   
8. Snip off the part that sticks out on the clip tabs.
   
   
   
   
   
   
9. Install on the ambient air temperature sensor onto the FMIC
   
       
   
   
   
10. That done you can re-install the grille.
    
    
    
11. If you aren't tuning your car with the appropriate map you'll need to plug-in the motor from the grille shutters and zip tie it somewhere it won't rattle loose or block the hood from closing.
    
    
    
12. You're all done!  Go out and enjoy!

1. Remove ambient air temperature sensor from grille by gently popping it out and unplugging the harness. 

   2018 only, later year vehicles will have the ambient air temperature sensor in a different position where it is not required to be moved.

   
   
   
   
   
   
   
   
   

2. Pop out the grille shutters one by one with a pry tool.
   
   
   
   
   
   
   
   
   
3. Remove the motor by pulling sideways on the flat end of the retaining clip by prying the clip away from the support.
   
   
   
   
   
   
   
   
   
4. Trim out the top edge along the line marked.
   
   
   
   
   
   
   
5. Trim the bottom edge up to the flat support fin shown in silver, do not cut through the fin itself..  Try not to go through it as it will add structural rigidity to what is left after.
   
   
   
   
   
   
   
   
   
   
   
6. Undo the bottom 3 plastic "nuts".  These are designed to cut into the plastic pegs so sometimes turning them to the left while prying upward helps them come off cleanly.
   
   
   
   
   
7. Remove the single 8mm bolt in the middle.
   
   
   
   
   
8. Remove the center shutter assembly
   
   
   
   
   
   
   
9. Install on the ambient air temperature sensor onto the FMIC
   
   
   
   
   
   
   
10. Install the outer clips for the rubber shroud but leave the middle out for now.
    
    
11. Begin to carefully install the grille without scratching the headlight trims.
    
    
12. when it's in place, reach up through the rubber and install the wiring harness into the ambient air temperature sensor.
    
    
13. Reinstall the rest of the grilles clips and bolts along with the lower skid tray.  Dont forget to check out all that free space!
    
    
    
    
    
    
    
    
14. You're all done!  Go out and enjoy!

1. Using a pry tool, pop out the center retainer for the shutters, then pop out each shutter until none are left
   
   
   
   
   
   
   
   
   
   
   
2. Remove the rubbery bottom piece on the grill shutter structure by popping the trim clips out of the bottom.
   
   
   
   
   
   
   
3. Remove the motor by pulling sideways on the flat end of the retaining clip by prying the clip away from the support.
   
   
   
   
   
   
   
   
   
4. While not completely necessary, you can remove the entire shutter support structure to trim if you're worried about hitting the grille.  To do so, you'll need to pop the front washer hose and camera connections out of the retaining clips by the grill shutter motor.  Simply lift up on the release tabs for them to slide out.
   
   
   
   
   
   
   
5. Undo the 2 10mm bolts on each side of the structure.
   
   
   
   
   
6. Pop out the trim clips along the top of ghe grille by pulling outwards on the raised center portion.
   
   
   
   
   
7. Once the grille shutter structure is removed, make sure the studs that hold it to the grille are slid back into place so you'll be able to reinstall tis structure after trimming.
   
   
   
8. Trim out the top edge along the line marked.
   
   
   
   
   
   
   
9. Trim the bottom edge.  You can either cut out the entire center section of the bottom, (along vertical yellow line) or leave a small amount of material that will still connect across and snap in.
   
   
   
   This is an approximation of what it would look like.
   
   
   
   
   
10. If you have an ADD or other bumper requiring a Adaptive Cruise Control module relocation now is a good time to install it.  We trimmed a small hole to allow getting to the connector more easily.
    
    
    
    
    
11. Reinstall the grill shutter support structure into the grille as well as the rubber bottom piece.
    
    
12. Test fit it up against the car and trim the lower rubber portion as needed.  While you can leave the rubber out, it will allow mud/dust/rocks etc. to get up onto the radiator and front mount so we chose to clearance ours to fit tightly against hte intercooler.
    
    
    
    
    
13. Begin to carefully install the grille without scratching the headlight trims.
    
    
14. Reinstall the rest of the grilles clips and bolts along with the lower skid tray.  Dont forget to check out all that free space!
    
    
    
    
    
    
    
    
15. You're all done!  Go out and enjoy!