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View Full Version : DIY - OEM Air BOX Modified for CAI with Replacement K&N



Mikeyas
16-09-2006, 10:52 PM
Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor Ozhonda take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!


Aim:
To Modify the Stock Integra GSI/Type R Air Box to intake colder air and do so with minimal cost and part replacement. Overall Completed job is VERY similar to the Comptech Icebox Minus the cost of course !!!!

Required:
- Philips head screw driver
- Socket wrench's
- Hacksaw
- Sandpaper
- K&N Replacement Air Filter
- Hammer
- Electrical/duct tape etc.

Steps:
As you can see below this is Before any work.
http://img156.imageshack.us/img156/698/enginebayhh6.jpg (http://imageshack.us)
Highlighted in Red is where orignially the intake would draw air from.
http://img147.imageshack.us/img147/2453/intakeholets6.jpg (http://imageshack.us)
All air from this location is hot and heatsoaked from the engine and not exactly what we want for our engines. Before the air gets to the engine it must travel down this hole and down into the bumper through the intake resonator and finally up to the filter, overall a very long and indirect process.

1. To start, you must remove the bumper. Remove the screws along the top of the bumper.
http://img95.imageshack.us/img95/4387/bumperboltsmx7.jpg (http://imageshack.us)
There is then two more bolts on either side to deal with.
http://img225.imageshack.us/img225/3176/bumperbolt2ye1.jpg (http://imageshack.us)
Next you must dive under the car and remove a further two bolts directly under the bumper, these are not hard to find, and well stick out like dogs balls ! Once you get these all off you have to get to the wheel well and pull the plastic aside and get on your back and look up.
http://img225.imageshack.us/img225/3641/wheelarchvy7.jpg (http://imageshack.us)
There is a philips head screw right up in there and can prove a bit of an effort to get to. Once all these bolts and screws are off you have to pull the bumper off, there are a few clips etc. but should be fairly straight forward.

2. I have not got any pictures of this process but will try explain as best i can the steps involed in removing the intake resonator. Once pulling off the bumper you will be presented with a big F*** off white box on the left side. There is 3 bolts to deal with here. One to the rear near the wheel arch, one to the fornt near the headlights and one behind it near the radiator. All except the front bolt are a B**** to get to and get off, due to limited room to do any de-boltifying. Once all de-boltified, you will have to disconnect the airbox from the intake arm with 3 easy to find bolts and get on with yanking the damn resonator out. I will not lie, this part is a B*** as well.. It just refuses to come out, but use your manly arms and give it some elbow grease and it should *should* come out.....

3. I also forgot to take pictures of this part. In order to remove the black U bend pipe you have to pull out your trusty hammer and beat the shit out of the intake resonator cracking the hard white plastic to pull out the black U shaped lower intake pipe. Once out take the U bend, go to a work bench and chop the thing in half.
http://img167.imageshack.us/img167/7853/inlet2lc1.jpg (http://imageshack.us)
Sand away Rough edges and BAM, lower intake arm complete.
http://img160.imageshack.us/img160/7971/inletyk3.jpg (http://imageshack.us)

4. Next you will need to get out some tape. I used black electrical tape in order to attach the lower intake arm to the air box.
http://img160.imageshack.us/img160/6862/airboxjointxi9.jpg (http://imageshack.us)
You have to attach this arm some how as before the parts would just sit together, due to the fact you have now removed and smashed :) the resonator holding everything up before. Here is the final Unit.
http://img167.imageshack.us/img167/6007/airboxoutmg2.jpg (http://imageshack.us)

5. Re-attach the air box reversing the previous steps to unbolt it. Also re-attach the bumper reversing its removal steps.

6. Now unscrew the top of the air box exposing the old stock filter:
http://img160.imageshack.us/img160/1909/oldfilterpz3.jpg (http://imageshack.us)
which is made in good old Japan....Thailand? :P
http://img167.imageshack.us/img167/4435/madeinthailandwb7.jpg (http://imageshack.us)
Take out this filter:
http://img160.imageshack.us/img160/4499/openboxbk1.jpg (http://imageshack.us)
and replace with the K&N Unit. The K&N comes with supplied grease to aid in getting the end back into the intake arm. THIS GREASE IS VERY USEFUL, as it is again an absolute B*** of a job to get this into the arm, use something to leaver this in and you will definatley swear less.
http://img167.imageshack.us/img167/6310/kninsidefs6.jpg (http://imageshack.us)
Attach the rubber gromet used on the stock filter to reduce vibration and reattach the top of the air box.

Here is the completed job.
http://img74.imageshack.us/img74/4343/finalro4.jpg (http://imageshack.us)

Other comments
After installing the car Revs alot smoother. Rev matching on down shifts is easier and it generally feels like the engine does not have to fight anymroe to breath. Intake sound is minimal compared to short ram but still very satisfying at higher revs and gives the engine an impressive note without being overbearing. Overall The car heads towards readline with more intesity and urgency.

Mikeyas
17-09-2006, 01:26 AM
Yeah i know and totally agree.. But i remembered to take pics after i did all that, thought id take pictures while putting in the new K&N and put up wahtever i could in the effort to hopefully inspire others to try themselves... heh

hey.. put it this way... If someone attempts it they can follow the instructions as is and maybe elaborate on design when they get down there. Hopefully there is enough detail for someone to follow though.....

turtleEK1
17-09-2006, 01:06 PM
choice write up dude! :thumbsup:

i got the same intake on my EK... but i used some flexipipe to run from the box to behind the bumper... plus had to fudge some mounts up (cable ties lol) to hold the box in the bay...

pretty damn sweet intake for an OEM intake! keeps the cops happy lol

egSi
17-09-2006, 01:55 PM
dc2 OEM intake = :thumbsup:

rock mine all day long with a K&N filter :thumbsup: :thumbsup:

nice writeup mate, is that a Gen. Honda filter?

Mikeyas
18-09-2006, 01:33 AM
elaborate on "Gen. Honda filter?"

kyle
18-09-2006, 07:50 PM
genuine

Mikeyas
18-09-2006, 08:05 PM
From what i can assume yes....

egSi
19-09-2006, 08:53 PM
From what i can assume yes....

really? thank god for K&N then lol mate :thumbsup:

reyesone
20-09-2006, 12:11 PM
yeah i had this mod done on my car for a while now, but always had the genuine honda air filter, gettin K&N filter soon though!

i'll get some photos of where the intake pops out and sucks the air from

when i have my window down, i can hear the suction easily cause its right next to the driver side window, sounds awesome!