Then attach the third pipe to the second pipe and make sure it makes a curve in the opposite direction. Attach the second pipe to the first pipe still attached to the throttle body, and make sure the second pipe curves down into the bumper hole. Once again, imagination and creativity come into play here.Īs you make each cut, keep assembling and test fitting the entire intake system. Once you are satisfied with the first piece, it’s time to complete the rest of the system. This is useful during rainy or winter months. Those worried about hydrolock and water, can convert their CAI into a “dry” system by simply bolting the filter onto this short piece of pipe. Make sure the straight part of the pipe goes perfectly towards the opening to the bumper where the resonator was. Once you have the fitting on, insert the pipe and clamp it down. You will have to wrestle it on, but it does fit, as in the following picture:
It’s a very tight fit, so it will help to lubricate the fitting using a rubber friendly lubricant like silicone grease or even a little bar soap). Now double-check everything by installing the first rubber pipe fitting onto the throttle body. When finished cutting, clean up any rough or sharp edges with the metal file and sandpaper. Use a hacksaw or cutting disc to make the cut, make sure it’s straight. You’re going to have to use your imagination and a little creativity here, but it’s not hard. Lay the pipe up against the throttle body, and eyeballed the proper angle that the pipe needed to be cut at. You can use the stock upper piece as a rough guide for making the cut. You can see from the following picture that the angle matches the stock intake angle. Please remove the bumper and all of the stock airbox componentsįirst clean all piping, once it is cleaned off, make sure it’s dry. You can buy the parts at you home improvement center when you are buying the PCV pipe clamps. Ø The grommet and hoses will be used to make the crankcase vent system. Ø Ceramic paint, go to any Auto Zone or Wal-Mart store, and buy “Dupli-Color” brand high-temp engine paint. They are about $20.00 at you local speed shop. Ø On the filter, you need a cone filter for the end of the tube to keep the dust out. The ones you need are for 2″ pipes, you will need 4 of them. Go to the PVC plumbing section, and look for “PVC Pipe Clamps”. They are made of durable, flexible, high-temp black rubber, and already have (2) stainless steel clamps integrated into them. Ø The rubber pipe clamps can be purchased at any home improvement Store also. This pipe can be bought at your local home improvement store or on the internet.
This single piece of pipe will be used to make the entire CAI system. Ø First, the tubing is a piece of mandrel-bent tubing. The total cost of the project is about $40 – $60 depending on shipping prices, the brand of filter you buy, etc. Ü 3/8″ ID rubber grommet, 3/8″ OD piece of plastic tube (about 4″ of tube), 5/8″ OD (3/8″ ID) piece of vinyl hose (about 12″ of hose) – see notes below Ü (1) can of Plasti-Coat ceramic high-temp engine spray paint – see notes below Ü K&N “Funnel Ram” Filter – see notes below
Ü (4) rubber PVC pipe clamps – see notes below Ü 180 degree mandrel-bent piece of steel tubing – see notes below
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