MX6.com - View Single Post - KLZE Intake Manifold (IM) Installation Guide

Omaha95PGT · 11-11-03, 7:16

1) The neck of the ZE IM is longer. Problems:

It will probably make your intake elbow run into the cruise control mechansism (CCM). Your options are to remove the whole CCM, move it to a different location or manipulate the TB elbow. I've heard of people moving the brackets of the CCM to make things fit. Modifying the TB elbow or elbow couplers may help as well

The throttle body's (TB) arm may be obstructed by the brake master cylinder fluid reservoir causing the throttle to stick open about 25%. This problem usually only occurs if you are using a phenolic spacer in between the IM and the TB. It may also occur on cars without the phenolic spacer due to differing fitments. Do not modify the brake fluid reservoir until you are sure that the arm does indeed get interfered with after installation. You must be sure that the arm clears the reservoir with at least 2-3 mm of clearance. A stuck throttle can be a deadly situation leading to property damage, injury and possibly loss of life. The solution is to shave down the area of the reservoir to allow for proper clearance. Do not perforate the reservoir. Do not shave the reservoir down until you know for sure that the throttle linkage is interfered with or does not have sufficient clearance. Here is a picture showing where I had to shave the reservior down:

The 2 small coolant hoses that go to the intake air control (IAC) are not long enough to reach the IAC. You have 2 options: 1) bypass the coolant that goes to the IAC by attaching the 2 hoses together with an adapter or remove one of the hoses and connect the other hose to the other coolant hardline. 2) buy longer coolant hoses (5/16") and replace the short ones. Cut to fitment and clamp the ends accordingly. Be aware that the coolant bypass mod may cause erratic idling problems in cold (usually subfreezing) weather due to icing of the throttle body. It will also cause prolonged high idling (~1500 rpm) due to the failure of the thermowax in the IAC to melt.

The rear valve cover vent hose is too short to reach the TB to VAF elbow. You have to replace the hose with a longer one. Use a 9/16" heavy guage heater hose so it does not collapse from the heat and vacuum. You will have to route the hose in such a way as to avoid the throttle arm. I had to loop the hose under and around the brake booster to get it to situate properly on the TB elbow's port in order to prevent the hose from kinking. Put a clamp on both ends of the hose to prevent slippage and vac leaks. It is best to install the hose to the piping (underneath) before you install the IM or else you will have one heck of a time trying to fit the hose on.

The IAC wires are too short. The ZE IAC has the connector pointing to the right rather than pointing downwards as on the 03. This will make it seem that you can't connect the IAC's wiring harness. The wires are long enough just release the wires from the main harness by either loosening up the electrical tape or very carefully cutting some of the harness' tape away to give the wires some slack.

11-11-03, 7:16	#2 (permalink)
Omaha95PGT Join Date: Jan 2003 Location: Chesapeake, VA iTrader: (0)	1) The neck of the ZE IM is longer. Problems: It will probably make your intake elbow run into the cruise control mechansism (CCM). Your options are to remove the whole CCM, move it to a different location or manipulate the TB elbow. I've heard of people moving the brackets of the CCM to make things fit. Modifying the TB elbow or elbow couplers may help as well The throttle body's (TB) arm may be obstructed by the brake master cylinder fluid reservoir causing the throttle to stick open about 25%. This problem usually only occurs if you are using a phenolic spacer in between the IM and the TB. It may also occur on cars without the phenolic spacer due to differing fitments. Do not modify the brake fluid reservoir until you are sure that the arm does indeed get interfered with after installation. You must be sure that the arm clears the reservoir with at least 2-3 mm of clearance. A stuck throttle can be a deadly situation leading to property damage, injury and possibly loss of life. The solution is to shave down the area of the reservoir to allow for proper clearance. Do not perforate the reservoir. Do not shave the reservoir down until you know for sure that the throttle linkage is interfered with or does not have sufficient clearance. Here is a picture showing where I had to shave the reservior down: The 2 small coolant hoses that go to the intake air control (IAC) are not long enough to reach the IAC. You have 2 options: 1) bypass the coolant that goes to the IAC by attaching the 2 hoses together with an adapter or remove one of the hoses and connect the other hose to the other coolant hardline. 2) buy longer coolant hoses (5/16") and replace the short ones. Cut to fitment and clamp the ends accordingly. Be aware that the coolant bypass mod may cause erratic idling problems in cold (usually subfreezing) weather due to icing of the throttle body. It will also cause prolonged high idling (~1500 rpm) due to the failure of the thermowax in the IAC to melt. The rear valve cover vent hose is too short to reach the TB to VAF elbow. You have to replace the hose with a longer one. Use a 9/16" heavy guage heater hose so it does not collapse from the heat and vacuum. You will have to route the hose in such a way as to avoid the throttle arm. I had to loop the hose under and around the brake booster to get it to situate properly on the TB elbow's port in order to prevent the hose from kinking. Put a clamp on both ends of the hose to prevent slippage and vac leaks. It is best to install the hose to the piping (underneath) before you install the IM or else you will have one heck of a time trying to fit the hose on. The IAC wires are too short. The ZE IAC has the connector pointing to the right rather than pointing downwards as on the 03. This will make it seem that you can't connect the IAC's wiring harness. The wires are long enough just release the wires from the main harness by either loosening up the electrical tape or very carefully cutting some of the harness' tape away to give the wires some slack. Last edited by Ruubstr94Ls : 8-6-06 at 23:30.