2009 Ford Flex CGS Intake Install

I decided to take the plunge and be one of the first ones on the forums to add a CGS Intake to my Flex. I did a full writeup on the install. I written my observations and posted install pictures below.

First let me say that the intake literally breaths new life into the engine. I did some before and after acceleration testing, as well not telling my wife what I had done and she noted both the increased intake noise and the boosted acceleration at WOT.

I have tracked the mileage of our Flex using my iPod Touch since our first fillup and we are currently at ~15,000 miles and ~21mph, so I will update this post after a few months of driving to see if it results in increased gas mileage.

Update: 8/15/10: We now have now driven about 10,000 miles with the intake and are achieving almost exactly the same mileage. Since we now do a little more city driving it is probably safe to expect a 1mpg improvement but not much.

In my quick analysis here are some of the benefits:

1. 1.Noticeable increase in power at WOT.
   

2. 2.Increased engine roar at WOT.
   

2. Potential for better mileage.

3. Lifetime filter that just needs cleaning and re-oiling every 20,000 miles or so.

As for the downsides the only one I noticed is the louder more noticeable noise of the intake under mid to heavy acceleration. Under light acceleration I can't hear a difference but at mid to heavy acceleration I can hear an increase in intake noise and a slight drone, which can get really annoying. At WOT the engine really roars and there is no doubt you can hear the sound of air rushing into the engine, I like the throatier sound but some may not want to deal with the drone when going up hills.

8/15/10 Update: I don’t notice the drone of the engine that much but enough people who have ridden with me have asked “what is wrong with your car” that I am considering removing the intake and going back to the factory system. Just an FYI.

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Before buying the intake I talked at length with Casey who owns CGS. In our discussion I learned a lot about intakes and I thought I would share some of it here.

Q: This isn't a 'cold air intake' so doesn't that mean it will be sucking in hot air from under the hood, and making less power? 

A: During the prototype stage we test with an air box drawing outside air and without the air box. If we find a performance difference then we use the air box otherwise we don't and therefore the intake costs much less to produce and sell. Also adding the box and intake plumbing reduces the airflow to the filter so in a lot of cases it is better to draw air from under the hood. Also once the vehicle is moving the under hood temp is generally within 1 degree of the outside temp and that is when you need the power not when stopped idling the engine.

Q: How do you clean the filter?

A: You can use any aftermarket filter cleaner kit, like the K&N filter cleaning kit. In fact the cone filter is the same as many other aftermarket offerings and can be replaced with a K&N cone filter as well.

Q: Why did you build an intake for the Flex?

A: We use a Flex here at the shop for running errands and we saw how restrictive the factory intake is. Plus we were chosen by Ford to build a customized intake and exhaust for a Flex that was shown at SEMA in 2008.

Finally Casey said that for those of us who order directly from the CGS website can get the Flex Intake (Part#20169) for $213 vs. the list price of $305. To get this pricing click on the Order link and then add to the comments section of the order page the promotional code: FordFlex.net Then simply enter the price as $213, or you can call Casey to place an order at 909-902-0102.