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

Omaha95PGT · 11-11-03, 7:19

3) The rectangular IM ports don't match the oval intake ports on my KL03 head. There are a several options: a) don't worry about it and just mount the IM up, b) buy a set of phenolic IM spacers from Outlaw Engineering and use a Dremel/rotary tool and a small barrel shaped sander attachment to port match the spacers in order to provide a gradual transition to the oval shaped ports (see post below for instructions) , c) remove your KL03 heads and port match the intake ports to match the ZE IM rectangular ports (very labor intensive and expensive, although I have heard a couple PT members porting their heads' intake ports while the heads were still installed in the car...watch for metal filings!), d) swap heads with a KLZE (very labor intensive and expensive)

4) The solenoid bracket from the 03 IM (consisting of the 2 VRIS solenoids and the EGR solenoid) doesn't mount anywhere on the ZE IM. Solutions: a) just zip tie it securely to something on the IM or the firewall b) remount the VRIS solenoids on the brackets provided on the ZE IM (one for each solenoid) and mount/zip tie the EGR solenoid at a place of your choice.

5) My front strut tower bar (FSTB) doesn't seem to fit anymore. This problem varies from car to car. It depends on how low your engine sits. The ZE IM sits higher than the 03 IM. You may be forced to remove the FSTB or have one custom made by RRE or your local race car fabrication shop. This style FSTB, goes behind the IM instead of above it. It is also one-piece and non-adjustable

6) My ZE IM rubs my hood. There isn't much you can do for it other than removing the IM and going back to the 03 IM or leave it as is. I guess you could shave some material off of the top of the IM's rear section, but you will risk perforating the wall of the IM.

7) My KL03 IAC has this big vacuum port that doesn't attach to anything, and now my idle is messed up. Solutions: a) get a large "T" to share the large vacuum port for the brake vacuum booster (this is not a recommended option...but if you do it, do not cut the brake booster's hose...it has a one way valve built into it), b) "T" into the PCV vac port on the neck of the IM (See instructions below) c) use a ZE TB and IAC, d) use a modified 03 TB and ZE IAC.

Note: Further installations by fellow PT'ers have shown that T'ing the vac for the brake booster will reduce the braking systems effectiveness. You may want to consider T'ing from the PCV port. But, it's recommended that you find a ZE IAC

11-11-03, 7:19	#4 (permalink)
Omaha95PGT Join Date: Jan 2003 Location: Chesapeake, VA iTrader: (0)	3) The rectangular IM ports don't match the oval intake ports on my KL03 head. There are a several options: a) don't worry about it and just mount the IM up, b) buy a set of phenolic IM spacers from Outlaw Engineering and use a Dremel/rotary tool and a small barrel shaped sander attachment to port match the spacers in order to provide a gradual transition to the oval shaped ports *(see post below for instructions)* , c) remove your KL03 heads and port match the intake ports to match the ZE IM rectangular ports (very labor intensive and expensive, although I have heard a couple PT members porting their heads' intake ports while the heads were still installed in the car...watch for metal filings!), d) swap heads with a KLZE (very labor intensive and expensive) 4) The solenoid bracket from the 03 IM (consisting of the 2 VRIS solenoids and the EGR solenoid) doesn't mount anywhere on the ZE IM. Solutions: a) just zip tie it securely to something on the IM or the firewall b) remount the VRIS solenoids on the brackets provided on the ZE IM (one for each solenoid) and mount/zip tie the EGR solenoid at a place of your choice. 5) My front strut tower bar (FSTB) doesn't seem to fit anymore. This problem varies from car to car. It depends on how low your engine sits. The ZE IM sits higher than the 03 IM. You may be forced to remove the FSTB or have one custom made by RRE or your local race car fabrication shop. This style FSTB, goes behind the IM instead of above it. It is also one-piece and non-adjustable 6) My ZE IM rubs my hood. There isn't much you can do for it other than removing the IM and going back to the 03 IM or leave it as is. I guess you could shave some material off of the top of the IM's rear section, but you will risk perforating the wall of the IM. 7) My KL03 IAC has this big vacuum port that doesn't attach to anything, and now my idle is messed up. Solutions: a) get a large "T" to share the large vacuum port for the brake vacuum booster (this is not a recommended option...but if you do it, do not cut the brake booster's hose...it has a one way valve built into it), b) "T" into the PCV vac port on the neck of the IM *(See instructions below)* c) use a ZE TB and IAC, d) use a modified 03 TB and ZE IAC. Note: Further installations by fellow PT'ers have shown that T'ing the vac for the brake booster will reduce the braking systems effectiveness. You may want to consider T'ing from the PCV port. But, it's recommended that you find a ZE IAC Last edited by Omaha95PGT : 11-11-03 at 8:23.