DIY - OEM Air BOX Modified for CAI with Replacement K&N
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
Highlighted in Red is where orignially the intake would draw air from.
http://img147.imageshack.us/img147/2...akeholets6.jpg
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/img95/438...erboltsmx7.jpg
There is then two more bolts on either side to deal with.
http://img225.imageshack.us/img225/3...erbolt2ye1.jpg
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/img225/3...eelarchvy7.jpg
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
Sand away Rough edges and BAM, lower intake arm complete.
http://img160.imageshack.us/img160/7971/inletyk3.jpg
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/img160/6...oxjointxi9.jpg
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/img167/6...rboxoutmg2.jpg
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/img160/1...dfilterpz3.jpg
which is made in good old Japan....Thailand? :P
http://img167.imageshack.us/img167/4...hailandwb7.jpg
Take out this filter:
http://img160.imageshack.us/img160/4499/openboxbk1.jpg
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
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
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.
