[Bobnoxious]

I have reposted this by request and pictures are a small file size for easy download and little server space.

KKM no longer sells the SVT for the Cougar, because they do not want to make the two simple modifications. I looked at the one Mortis bought in 1999 and realized these would be easy to do myself, and extra parts were only $10.00.
First go to the KKM Tru-rev website via the performance section of the NECO site (not the message board). Print the fax order from and put down that you have a Contour, no need to call and hassle. They won’t sell the parts to do the modifications. Fax it in, and you will receive your kit in a few days. Go to your local hardware store (Home depot is where I went) and buy the following parts:
PlumbQwik P1056-33 3” to 3” hose ($8.00)
½ X ¼ plastic barb coupling (.89 cents)
One foot or shorter ¾ OD X ½ ID vinyl tube (.99 cents) you need at least an inch.
Tools:
Flat head screw driver
Hole punch or Phillips head screw driver (not pictured)
11MM and 8MM sockets or wrenches
Drill with ¼” bit.
Fender cover

 

[Bobnoxious]

1.
Cover your fender. Disconnect the negative wire to the battery. Remove the ITA sensor, on the right side of the stock air box. Remove the wire connection on top of the silver pipe between the air box and engine (MAF). At the end of the step, it should look like this picture.

 

[Bobnoxious]

2.
Loosen the clamp around the MAF. Unlatch all of the clamps around the stock air box, and gently work the MAF & top of the air box out. It should now look like this:

 

[Bobnoxious]

3.
Remove the bottom of the stock box and put the blue KKM tube on the boot coming out of the finder.

 

[Bobnoxious]

4.
Use a ¼ drill bit to drill a hole in the black boot behind the K & N filter. Please, make sure you have the kit right side up and you are drilling on the correct side (right). Make the hole a little about half way up on that side. Use a hold punch or Phillips head screwdriver to make the hole a little bigger. Push the small side of the plastic coupling into the hole.

 

[Bobnoxious]

5.
Cut an inch long piece of the vinyl tube and push it on the other end of the coupling. Then gently push the ITA sensor in the other side of the tube.

 

[Bobnoxious]

6.
Take the 3” to 3” hose and push it over the KKM blue tube by the fender.

 

[Bobnoxious]

7.
Unbolt the MAF from the stock air box and bolt it to the KKM kit. A little metal bracket is supplied and goes on the bottom right bolt. I put the bracket on but it is to short to connect to anything, and the intake hose will support the kit enough.

 

[Bobnoxious]

8.
Gently work the other end of the kit into the 3” to 3” hose. Then tighten all three clamps. 1 on the MAF and two on the hose. It will fit better if you slightly bend the clamp near the fender to a more oval shape. Then reconnect the MAF and ITA wire.

 

[Bobnoxious]

9. You’re done, and this is a look from the front of the engine bay.

 

[Bobnoxious]

Ready to roll, and you will love the sound. Good luck and feel free to email me.
PS. There have been posts of other ways to connect the ITA sensor, but I believe you will still need to make the mods to make it work.

Below is a pic after recently cleaning the filter, passing state emissions inspection and a year of service!! Enjoy..

 

[Guest]

THANK YOU!!!!!!!

 

[Bobnoxious]

No problem. Please keep in mind that if you are installing the non SVT KKM. I did not put any instructions in on the support bracket. In this version the tube supports the filter, so the braket isn't really needed. If you are using the other filter. I would recommend loosely attaching the braket and setting the set up in place. Then play around with the bracket till you find the right spot before tightening everything down!

 

[Guest]

Yes, if you've got the non SVT version, make sure you have a clamp and something to bend the bracket with, as it will more than likely NOT fit anywhere near perfectly.

 

[Guest]

Yea, the non- svt wouldn't work. I have the svt version. thanks!

 

[Guest]

I have a K&N. Does the KKM perform better? If I install the KKM, does this mean I have to get rid of the K&N? Finally, I noticed on KKM'S Web-site that they sell the SVT for the 2.5L Duractec Contour SVT. If available, can we use that on the Cougar? I ask because on your reply you stated to simply say you have a Contour - that way no problems and you get the SVT? How much additional horsepower does it produce and how loud does it sound?

Thanx for your help and advice.

 

[Guest]

I can't say if the kkm is better than the k&n, but if you tell them you have a cougar when you order, they'll tell you they don't make the svt for the cougar. maybe they will let you order the countour kkm,i'm not sure. give it a shot

 

[Bobnoxious]

I would fax in the order or call saying you have a Contour SVT if that is the style you want. The KKM is the K & N filter SVT or NON, their adapter plate, and a support braket. If you mean you have a K & N filter in your stock air box then it would most likely be louder. Look at the pics and you can see the K & N style filter that is used. This how to is for ordering the SVT style and making the little modification necessary for it to work on the Cougar. They used to sell it for the Cougar but I guess they got tired of making the small modification themselves.

 

[Guest]

Bobnoxious, I just installed the conversion. For about 3 weeks I had just the filter in place and the AIT hanging in the bay because I didn't know what I needed to get. Now I got the pieces needed and put em in. I now have 3 problems. 1-When at idol the car is fine, but when I give it a little juice the car almost stalls, then picks up and hauls butt. It olny does this in low rpms. 2-I seem to have to press the pedal a little bit more to get a response. 3-I have severe throttle hang now. Do you know what can be causing this? Thank you.

 

[Guest]

I know what the problem is. I forgot to reconnect the MAF sensor. It runs fine now. Damn I'm stupid