Air Induction Kit - Fitting

**Artful** · 5-31-05, 19:50

Took her out tonight and gave her proper good seeing to. Its all a bit
subjective without a dyno I guess but she seems to have a bit more poke
throughout and makes a great sound when your foot is on the floor. Deff gets
the

from me. More addictive than ever......

Anyway I took a few pics while fitting - may be of use to someone.

this is what turned up from Jaxracing - 1 filter, 2 pipes, 3 blue rubber collars,
enough big jubillee clips and some odd metal brakets.

I decided to do the banjo mod and fuel filter while i had it apart and this is
where the fule pump relay was just after I removed it - see kens banjo write
up for the details.

my (dirty) engine bay before std filter removal - undo all the clips and bolts
where there are red arrows

side view showing the breather/vacum hoses at the back and a few more
bolts to undo

then just lift it all out and you are left with this. red arrow point to the mount
I reused later - blue arrow point towards banjo bolt area (note even after
depresuring the system the fuel will still pi$$ everywhere so make sure it's all
cooled down and have plenty of rags to hand - and the trusty fire
extinguisher!)

while it's apart lets check out the crud in the throttle body - unlike me make
sure you get some throttle body cleaner to hand before you start and clean it
all out as described elsewhere (my halfords didnt sell it - so its on the to do
list)

On the top of the air box undo the two screws where the red arrow point and
pull the MAF sensor in the green direction.

once removed turn it over and undo the small screw - allowing you to remove
the metal body (note some may prefer to leave this in place and use it to
mount the brackets to - your choice)

actual fitting was a bit of trial and error but its all pretty obvious once you
start fitting bits together - I removed my battery to make more space while
fitting and tried to remove the battery tray which would have helped get the
cone filter in - in the end I just fitted the cone filter to the long pipe and
passed it up from underneath the splash tray

red arrows point to the bodge up bracket I made using the suplied brackets
and also the all important MAF connector refitted - recon it will run a bit odd
without it! so dont forget.

top shot of my bent bracket (note it mounts to the left over stud from the old
air box - I also reused a couple of the bolts from the old airbox mounts)

and again from another angle - you can probably find a better solution, just
remember it must be fitted to the engine somehow, not the chassis as it must
move as the engine moves.

dont forget to refit both breather/vacum hoses. The small hose is now a very
tight fit so add some new vacum pipe to the shopping list

simply a top shot looking down to the filter

and seeing the filter at the bottom from the front of the splash tray - there is
a handy hole here to give a good supply of fresh air - not sure about water
splashing on the fiulter direct though in rainy conditions?? your comments on
this please ??

and the final job with the battery back in place - plus dont to refit forget the
green fuel relay - shown with the red arrow - as I found out it doesn't start
too well without it...

Obviously while all this was going on the battery was disconnected so would
have reset the ECU - I you dont remove the battery I think your should still
reset the ECU as it remaps? for the new fuel and filter setup - but I'll let
someone more techy explain that one. Hope that helps those who weren't
sure about taking the plunge - not to difficult.

One final point regards the insurance - I choose to add both intake mods and
exhaust mods (for the scorpion) to my policy (Admiral) for which they charged
another £37 in total. If I ever have the missfortune to stuff it the last thing I
want to have to do is try and refit the old bits while its sitting in a ditch or
worse. Not worth the risk IMO.

Artful...

**mattsonthebeach** · 5-31-05, 20:25

My CAI has been in the same position as yours since Japfest last year without any problems. You just need to steer clear of giant puddles and floods

stuzzer · 6-1-05, 2:33

looks like a nice bit of kit for the £, if it fitted without any trimming etc thats a result too.

**pompeydel** · 6-1-05, 2:54

I want one........

**rasheedn** · 6-1-05, 4:07

thats sweet! great write up!! seriously this has 2 be the best one i've ever seen!
great pictures too

**cold_fusion** · 6-1-05, 6:50

very nice fit!

esp since you can see it at the bottom for a supply of fresh air, and even managed to use the fitted backet!

very sweet!

**ElmerFud** · 6-1-05, 15:53

nice one artful. Looks exactly like mine except the bodge bracket. Must get pics to show you guys. I've had mine sinceNovember and no probs with water ingress... just as already stated above, steer clear of near side road puddles. I've heard someone hydrolocked their engine when they went through a massive puddle.

ElmerFud

**Artful** · 6-2-05, 7:10

Cheers for the feedback guys - see the other intake thread for my comments regards Jax. Do get one from somewhere though, deffinitely makes a worthwhile difference. I'll try and get the Jax dials done soon and do another how-to.

Artful/Chris

David MX-6 · 3-2-07, 2:22

Anyone know where i can get the chrome 90 bend pipes separate as i dont need the cone filter ?

**Oddball** · 3-2-07, 2:35

As you have an auto box, the down pipe and filter will not fit down there, you will have to use one of the shorter systems comprising of just the throttle body elbow and then a filter connected to the VAF. Try ebay for the shorter systems, or even try www.fordprobestore.co.uk to see if they have anything in stock.

Oddy.

vwgolfgtimkii · 3-2-07, 4:58

My CAI sucks, just got one chrome pipe to put after the MAF and its kinda short so the filter is wedged in between the radiator and battery tray, gonna take it off soon, got the kit off ebay, needless to say im a bit peeved off

David MX-6 · 3-2-07, 11:02

Quote :- filter is wedged in between the radiator and battery tray.

Ditto same here will spend a bit of time here hence the request for the 90 bend , will try and get it back into the ram air duct on the bonnet slam panel ? What do you think ?

APL · 3-5-07, 8:54

Good Job!

I made a bracket simlar to that.

My induction kit was for a saxo VTR but I bodged it to work.

Now sucking nice cool air from down in the front left corner.

Some guys may be interestd to know that most suto manufactures consider this to be the optimum position for an intake system, something to do with air stagnation positions????

Well done again!

A!

**L20KEV** · 8-19-08, 7:20

Hi, I've got mine set up the same as the above. My MOT man said that the filter is too low and I could ruin the engine (as stated above if not careful with puddles).

If there anything i can do to prevent this??
Any modifications to the pipe etc??
How bout cutting 3" off the down pipe length?

**Oddball** · 8-19-08, 8:58

You would have to submerge the filter in water for any serious hydroloc, small puddles and splashes should be fine. I ran mine for 3 years like that and the splash shield protecting it from most problems... just have to remember when driving, and if you reach a flooded section of road, either turn around, or go up the kerb.

Paul.

5-31-05, 19:50	#1 (permalink)
Artful Join Date: Mar 2004 Location: Surrey, UK Age: 36 iTrader: (0)	Jaxracing CAI installation Took her out tonight and gave her proper good seeing to. Its all a bit subjective without a dyno I guess but she seems to have a bit more poke throughout and makes a great sound when your foot is on the floor. Deff gets the from me. More addictive than ever...... Anyway I took a few pics while fitting - may be of use to someone. this is what turned up from Jaxracing - 1 filter, 2 pipes, 3 blue rubber collars, enough big jubillee clips and some odd metal brakets. I decided to do the banjo mod and fuel filter while i had it apart and this is where the fule pump relay was just after I removed it - see kens banjo write up for the details. my (dirty) engine bay before std filter removal - undo all the clips and bolts where there are red arrows side view showing the breather/vacum hoses at the back and a few more bolts to undo then just lift it all out and you are left with this. red arrow point to the mount I reused later - blue arrow point towards banjo bolt area (note even after depresuring the system the fuel will still pi$$ everywhere so make sure it's all cooled down and have plenty of rags to hand - and the trusty fire extinguisher!) while it's apart lets check out the crud in the throttle body - unlike me make sure you get some throttle body cleaner to hand before you start and clean it all out as described elsewhere (my halfords didnt sell it - so its on the to do list) On the top of the air box undo the two screws where the red arrow point and pull the MAF sensor in the green direction. once removed turn it over and undo the small screw - allowing you to remove the metal body (note some may prefer to leave this in place and use it to mount the brackets to - your choice) actual fitting was a bit of trial and error but its all pretty obvious once you start fitting bits together - I removed my battery to make more space while fitting and tried to remove the battery tray which would have helped get the cone filter in - in the end I just fitted the cone filter to the long pipe and passed it up from underneath the splash tray red arrows point to the bodge up bracket I made using the suplied brackets and also the all important MAF connector refitted - recon it will run a bit odd without it! so dont forget. top shot of my bent bracket (note it mounts to the left over stud from the old air box - I also reused a couple of the bolts from the old airbox mounts) and again from another angle - you can probably find a better solution, just remember it must be fitted to the engine somehow, not the chassis as it must move as the engine moves. dont forget to refit both breather/vacum hoses. The small hose is now a very tight fit so add some new vacum pipe to the shopping list simply a top shot looking down to the filter and seeing the filter at the bottom from the front of the splash tray - there is a handy hole here to give a good supply of fresh air - not sure about water splashing on the fiulter direct though in rainy conditions?? your comments on this please ?? and the final job with the battery back in place - plus dont to refit forget the green fuel relay - shown with the red arrow - as I found out it doesn't start too well without it... Obviously while all this was going on the battery was disconnected so would have reset the ECU - I you dont remove the battery I think your should still reset the ECU as it remaps? for the new fuel and filter setup - but I'll let someone more techy explain that one. Hope that helps those who weren't sure about taking the plunge - not to difficult. One final point regards the insurance - I choose to add both intake mods and exhaust mods (for the scorpion) to my policy (Admiral) for which they charged another £37 in total. If I ever have the missfortune to stuff it the last thing I want to have to do is try and refit the old bits while its sitting in a ditch or worse. Not worth the risk IMO. Artful... Last edited by Artful : 5-31-05 at 20:46.
	Chris/Artful A few pics of my 6 here > Artfuls MX6 Page

5-31-05, 20:25	#2 (permalink)
mattsonthebeach Join Date: Sep 2003 Location: Newport, UK Age: 35 iTrader: (0)	My CAI has been in the same position as yours since Japfest last year without any problems. You just need to steer clear of giant puddles and floods
	Matt Quietly modding! What's that coming over the hill? Is it a Mazda? Is it a Mazda

6-1-05, 4:07	#5 (permalink)
rasheedn Racing for team Palestine Join Date: Apr 2005 Location: Jerusalem, "Palestine" Age: 24 iTrader: (0)	thats sweet! great write up!! seriously this has 2 be the best one i've ever seen! great pictures too
	RUSHING RASHEEEEEED 2004 Subaru Impreza WRX STI SS brake lines,carpc,remap, F&R antiroll bars, anti-lift kit, SS exhaust system, (VF 37 Twin scroll turbo equal length headers, 50/50 meth injection and RCE Tarmac 2 Coilovers

6-2-05, 7:10	#8 (permalink)
Artful Join Date: Mar 2004 Location: Surrey, UK Age: 36 iTrader: (0)	Cheers for the feedback guys - see the other intake thread for my comments regards Jax. Do get one from somewhere though, deffinitely makes a worthwhile difference. I'll try and get the Jax dials done soon and do another how-to. Artful/Chris
	Chris/Artful A few pics of my 6 here > Artfuls MX6 Page

3-2-07, 2:35	#10 (permalink)
Oddball Join Date: Jun 2003 Location: kent, UK Age: 40 iTrader: (3)	As you have an auto box, the down pipe and filter will not fit down there, you will have to use one of the shorter systems comprising of just the throttle body elbow and then a filter connected to the VAF. Try ebay for the shorter systems, or even try www.fordprobestore.co.uk to see if they have anything in stock. Oddy.
	Current Ride and new project- 93 Cavalier Turbo, running approx 260 at 12psi on phase one chips. ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ R.I.P 92 2nd gen HYBRID - ZE cams, ZE inlet manifold, Mag leads, 65mm TB, CAI, Tokico shocks springs, SS headers, SS DE-cat, SS Scorpion cat back, 17in Wolfrace Osaka alloys - pics ==>My Album

6-1-05, 2:33	#3 (permalink)
stuzzer Banned Join Date: Aug 2004 Location: melton mowbray, UK Age: 35 iTrader: (0)	looks like a nice bit of kit for the £, if it fitted without any trimming etc thats a result too.

6-1-05, 2:54	#4 (permalink)
pompeydel Join Date: Apr 2005 Location: Nr Portsmouth, UK iTrader: (2)	I want one........

6-1-05, 6:50	#6 (permalink)
cold_fusion Join Date: Aug 2004 Location: Kingston, Surrey, UK Age: 25 iTrader: (0)	very nice fit! esp since you can see it at the bottom for a supply of fresh air, and even managed to use the fitted backet! very sweet!

6-1-05, 15:53	#7 (permalink)
ElmerFud Join Date: Sep 2004 Location: Fife, Scotland Age: 39 iTrader: (1)	nice one artful. Looks exactly like mine except the bodge bracket. Must get pics to show you guys. I've had mine sinceNovember and no probs with water ingress... just as already stated above, steer clear of near side road puddles. I've heard someone hydrolocked their engine when they went through a massive puddle. ElmerFud

3-2-07, 2:22	#9 (permalink)
David MX-6 Join Date: Feb 2007 Location: Whitland,Carmarthenshire, Wales, Uk Age: 46 iTrader: (0)	Anyone know where i can get the chrome 90 bend pipes separate as i dont need the cone filter ?

3-2-07, 4:58	#11 (permalink)
vwgolfgtimkii Join Date: Feb 2007 Location: Huddersfield, UK Age: 28 iTrader: (0)	My CAI sucks, just got one chrome pipe to put after the MAF and its kinda short so the filter is wedged in between the radiator and battery tray, gonna take it off soon, got the kit off ebay, needless to say im a bit peeved off

3-2-07, 11:02	#12 (permalink)
David MX-6 Join Date: Feb 2007 Location: Whitland,Carmarthenshire, Wales, Uk Age: 46 iTrader: (0)	Quote :- filter is wedged in between the radiator and battery tray. Ditto same here will spend a bit of time here hence the request for the 90 bend , will try and get it back into the ram air duct on the bonnet slam panel ? What do you think ?

3-5-07, 8:54	#13 (permalink)
APL Join Date: Jun 2006 Location: Kingston Upon Thames, UK Age: 23 iTrader: (0)	Good Job! I made a bracket simlar to that. My induction kit was for a saxo VTR but I bodged it to work. Now sucking nice cool air from down in the front left corner. Some guys may be interestd to know that most suto manufactures consider this to be the optimum position for an intake system, something to do with air stagnation positions???? Well done again! A!
	Hampshires Finest

8-19-08, 7:20	#14 (permalink)
L20KEV Join Date: Feb 2007 Location: Doncaster, South Yorkshire, UK Age: 25 iTrader: (0)	Hi, I've got mine set up the same as the above. My MOT man said that the filter is too low and I could ruin the engine (as stated above if not careful with puddles). If there anything i can do to prevent this?? Any modifications to the pipe etc?? How bout cutting 3" off the down pipe length?
	1996 Manual 2.5GT (still running great, but still needs the paperclip fitted to FP & GND in diagnosis box to run)

8-19-08, 8:58	#15 (permalink)
Oddball Join Date: Jun 2003 Location: kent, UK Age: 40 iTrader: (3)	You would have to submerge the filter in water for any serious hydroloc, small puddles and splashes should be fine. I ran mine for 3 years like that and the splash shield protecting it from most problems... just have to remember when driving, and if you reach a flooded section of road, either turn around, or go up the kerb. Paul.
	Current Ride and new project- 93 Cavalier Turbo, running approx 260 at 12psi on phase one chips. ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ R.I.P 92 2nd gen HYBRID - ZE cams, ZE inlet manifold, Mag leads, 65mm TB, CAI, Tokico shocks springs, SS headers, SS DE-cat, SS Scorpion cat back, 17in Wolfrace Osaka alloys - pics ==>My Album