702100 - COBB Tuning Intake System

2014 - 2019 Ford Fiesta ST

Congratulations on your purchase of the COBB Tuning Intake System for the Fiesta ST! The following instructions will assist you through the installation process. Please read them BEFORE beginning the install to familiarize yourself with the steps and tools needed. If you feel you cannot properly perform this installation, we HIGHLY recommend you take the vehicle to a qualified and experienced automotive technician.

Parts List

1 x Cone Filter with Clamp
1 x Large Tube – Logo
1 x Small Tube – MAF
1 x 7/8” Vent Tube – 34”
1 x COBB Airbox Lid
1 x 90* Barb Vent – Plastic
2 x 8-32 x ¾” Screw (MAF)
2 x ½” - 1.25” Clamp
3 x 2.5” – 3.5” Clamp
1 x 2.25” – 3.25” Clamp (Turbo)
1 x Mounting Bracket
1 x Silicone Reducer Coupler
1 x Silicone Straight Coupler
1 x M8 x 12mm Bolt
1 x 8mm Lock Washer
1 x 8mm Flat Washer
1 x M6 Flange Nut
1 x 6mm Fender Washer
1 x COBB License Plate Frame
2 x COBB 6” Sticker
COBB Tuning 2016-2017 Fiesta ST Intake Adapter Kit

Tools Needed

¼” Ratchet
10mm Deep Socket
8mm Socket
7mm Socket
15mm Socket
12mm Wrench
T30 Torx Bit
T25 Torx Bit
T20 Torx Bit
Flat-head Screwdriver
Pliers
Phillips Head Screwdriver
6” Socket Extension
¼” Universal Joint

Removing Factory Intake

To start off, it’s best to go ahead and unplug the negative battery cable from the battery. You will need a 10mm socket or wrench to do so.
Pull the engine cover off of the motor by pulling upward and away. It’s held in place by three (3) grommets that will pop out with force.
Remove the two (2) rubber caps off of the base of the windshield wipers. Use a 15mm socket to remove the nut holding each wiper to the vehicle. Remove the wipers by wiggling them back and forth off of their spline. This may require the use of a small bearing puller type tool.
Pro Tip: Use blue painters tape to mark where the wipers rest in a down position so that it’s easy to reinstall later.
Using a small pick or a small flat-head screwdriver, pry off the six (6) clips that hold the two layers of cowl together and set them aside. Remove the top cowl piece and set aside.
Using a T30 Torx bit, remove the two (2) screws that hold each headlight on. Use a flat-head screwdriver to remove the plastic fastener as well. Starting at the back of the light, pull upward on the headlight until it pops free. You may need to push the headlight toward the windshield to release the upper clip. Unplug the plug on the back of the headlight and set it aside. Remove both headlights.
With the headlights out of the way, use a 10mm socket, remove the two (2) fasteners on each end of the lower cowl section. Once all four (4) fasteners are removed, use your fingers to pinch and remove the line in the center of the cowl and remove the cowl.
With the cowl finally out of the way, we can now remove the factory intake. Use a 10mm socket to remove the nut holding down the intake to the valve cover. Use a 12mm wrench to remove the plastic engine cover mount that is also holding the intake in place at the back of the motor.
Use a 7mm socket to loosen all three (3) of the worm clamps on the intake. There is one behind the motor where the intake meets the turbo as well as one clamp where the two intake tubes meet and one clamp that secures the tube to the airbox.
a) If you have a 2014-2015 MY use a pair of pliers to pull the PCV hose off of the valve cover. (Refer to the picture on left)

b) If you have a 2016-2017 MY, un-clip the PCV hose from the stock intake tube by squeezing the plastic ring and pulling away from the tube. (Refer to picture on right)

2014-2015 MY 2016-2017 MY
a) If you have a 2014-2015 MY remove the tube at the start of the intake by disconnecting the connector with the green clip and pulling it away from the intake. Pull back the red tab on the MAF sensor attached to the airbox and unplug the sensor. (Refer to picture on left)

b) If you have a 2016-2017 MY remove the two (2) connectors with the green clips and pull back the red tab on the MAF sensor attached to the airbox and unplug the sensor. With your hand, follow the hardline coming from the larger of the two connectors until you find the clip connecting the other end to the lower intercooler piping. Unclip this and remove the entire stock hardline. Remember where this connection is as you will need to connect the intake adapter to it later. (Refer to picture on right).

2014-2015 MY 2016-2019 MY
With all the connections and clamps loose on the intake, break the two tubes apart and remove the intake from the car.
Using a T20 Torx bit, remove the four (4) screws holding the top of the airbox onto the lower part of the box. Once removed, remove the MAF sensor from the box using a T20 Torx bit.

Installing the COBB Intake

Using the supplied Phillips head screws, reinstall the MAF sensor into the smaller COBB intake tube. On the same tube, use a wrench to ensure that the metal breather fitting is securely installed as well.
On the larger COBB tube, ensure the plastic PCV fitting on the back of the tube is snug and pointing towards the end of the word COBB on the tube.
Loosely install the reducer coupler and one (1) 3” clamp and one (1) 2.5” clamp onto the end of the larger COBB tube and loosely install it over the turbo. Leave it a little loose for now so we can make adjustments later.
Place the new COBB airbox lid over the smaller tube and install the filter onto the end of the tube. Place the clamp for the filter just on the other side of the bead roll on the tube to ensure best fitment. Pushing the filter too far onto the tube can cause fitment issues.
Install the filter and airbox lid into the airbox and secure with the factory Torx screws. You may need a universal joint to install the top/left screw.
If it’s not already installed, place the 3” straight silicone coupler along with two (2) 3” clamps between the two tubes and slide the tubes into the silicone coupler. You may need to adjust how far into the silicone each tube is at this connection as well as at the turbo to get the best fit for the intake. Once you’re comfortable with the fitment, go through and tighten all the worm clamps on the intake with an 8mm socket.
Using the supplied bracket, use a ½” socket on the intake side and a 10mm socket to secure the bracket to the factory intake mounting position with the fender washer and 10mm nut. If this bracket can't be tightened properly, you can loosen the worm clamps on the intake tubes and adjust the intake tube so that the bracket is aligned better and then adjust your silicone couplers and re-tighten the clamps.
Install the supplied 7/8” tubing onto the plastic barbed fitting on the back of the intake and tighten it down using the supplied worm clamp.
Now it's time for the pcv tube itself.
1. 2014-2015 MY Feed the tubing beneath the COBB intake and wrap it around to meet the opening in the valve cover from the factory PCV pipe. Install it over the opening and secure with the supplied clamp. Trim the tube if necessary for optimal fitment.
2. 2016-2019 MYFeed the tubing beneath the COBB intake and wrap it around to meet the stock PCV tube coming from the valve cover. Mark the point where the two meet on the 7/8" tube and cut the tube to this length. After cutting the tube it should be approximately 14" long. Next slide the other worm clamp on the 7/8" tube and insert the supplied aluminum PCV adapter to the stock enduntil you hear a click.
  
  Then route the new COBB hose under the intake to meet up with the new PCV connection. The stock head will rotate a little to make them meet up correctly. You can adjust the final position of the connection later for best fitment.
This step is only for 2016-2019 MY. Now that everything is in place you can connect your intake adapter. Before beginning, check that the flow direction arrow on the small check valve next to the Tee fitting is pointing toward the Tee fitting on the adapter. There is also a small aluminum insert inside of the tee fitting on the side with the longer hose. Check that this insert is fully seated into the tee fitting by squeezing the long silicone hose near the fitting. If it feels like there is a cylindrical piece protruding from the tee fitting more than 1/4", it is likely that this insert is not fully seated. If this is the case, you will need to remove the long silicone hose from the tee fitting and seat the aluminum insert. This can be done by pushing the thin end of the insert into the tee fitting and pressing firmly on the end with your thumb until the thinner portion of the aluminum insert is no longer visible and you have reached a hard stop. Once the insert is seated you can replace the hose and continue with your install. Begin by connecting end (1) to the port on the intake tube. Then connect end (2) to the intercooler pipe where you removed the stock hardline form earlier. End (3) will connect to the remaining stock hardline. The routing should look like the picture on the right when completed.

2016-2019 MY 2016-2019 MY
Finally, go back and double check all your connections to ensure everything is tight on the intake. There are a total of six (6) worm clamps. Two on the turbo connection, two between the two tubes, and two on the PCV hose. You may need to cut the tape on your MAF sensor plug to allow it to reach the new MAF sensor position. Be careful not to cut any of the wires. On 2014-2015 MY make sure the connector with the green clip is connected to the port on the intake tube. On 2016-2017 MY make sure all three adapter connectors are clipped shut and securely attached.
Reinstall the cowl, wipers, and engine cover in the reverse order from how they were removed. The top cowl portion will need to be pushed up into place onto the windshield.
Make sure to use your Accessport to flash the appropriate map for your new intake and get out there and enjoy it!