K&N AirCharger CAI Install (w/pics & vid) (Full Version)

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K&N AirCharger CAI Install (w/pics & vid)

  

TacoBill -> K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 12:36:47 PM)

Review:  This is a great CAI system that doesn''t require a tune (However, your tuner can provide you with a custom tune that''ll maximize this CAI''s potential).  It doesn''t produce as much HP gains as some of the CAI kits currently on the market, but I still like this K&N system as it''s a definite improvement over stock. K&N CAI install
63-2565

This K&N AirCharger kit does not require a tune and will provide you with a gain of 18-rwhp and 15-rwtq (reference Tech Article).

This install is pretty straight forward and shouldn''t take more than an hour to complete.


Stock set-up.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7436.jpg[/image]


Remove the crankcase breather hose from the passenger side camcover by rotating the green locking tab. Loosen the hose clamp at the throttle body and at the factory air box. Note that both clamps are locked in via notches in the air duct. Once loose, just slip it over the notches.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/crankcasehose.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7454.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7455.jpg[/image]


Once the air duct is removed, you’ll have a good view of the throttle body and MAF sensor. You can disconnect the MAF sensor plug at this time by sliding the red lock latch back.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7456.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7457.jpg[/image]


Remove the factory airbox by removing the mounting bolt.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/airboxmountingbolt.jpg[/image]


Remove the 2 camcover bolts as shown. Once these bolts are loose, you’ll need to yank up on them pretty hard because of the rubber inserts.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7458.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7461.jpg[/image]


Assemble the air tube support saddle (per directions) to the black bracket and positions the 2 camcover bolts in it.
** Note: It has been brought to my attention that this particular bracket will NOT fit to the 2007 (and subsequent) camcover due to a redesign. Contact K&N to see if they can supply the correct bracket.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7460m.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7462.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7475.jpg[/image]


(At the time of write-up, I chose not to install the heatshield, but decided to install it when I did the Shaker)
At this point, assemble the supplied ‘L’ brackets to the heatshield and install it per the supplied directions.
Couple notes, installing the foam edge trim around the perimeter of the shield is a major pain. Sure you can just throw it on, but if you want it to come out show quality, forget it (main reason why I left it off, looks much cleaner without it).
The heatshield picks up one of the radiator shroud bolts. Re-installing this bolt can be another pain, just take your time and watch for cross-threading.

Carefully transfer the MAF sensor from the factory airbox to the K&N air tube.
Take note of the ‘Flow’ direction and transfer it exactly the same.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7463.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7464.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7467.jpg[/image]


Install the silicone sleeve/hose onto the throttle body and position the 2 supplied clamps, keep them loose.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7469.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7471.jpg[/image]


Slip the other supplied clamp over the air tube that will attach it to the saddle support and position it into the throttle body sleeve.
Once in position, tighten down the 3 hose clamps.
Note: Do not over tighten the hose clamps on the throttle body. If you do, the airtube will compress (remember it’s plastic) and may pop out (this is a bad thing).
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7474.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7472.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7477.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7478.jpg[/image]


Install the supplied vent hose to the side of the airtube and the other end to the breather valve on the camcover.
Note: In the early release airtubes (incase you bought old stock or a used unit), the connector on the side of the airtube had a manufacturing defect. When molded, the hole was blocked or was too small. This will throw a CEL and cause the engine to not run right. If blocked, get a drill about the same size of the inside diameter and drill through the blockage. Make sure you remove all the plastic shavings when done.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7482.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7483.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7484.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7490.jpg[/image]


Install the cone air filter onto the adapter then install it onto the airtube.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7486.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7488.jpg[/image]


Re-connect the MAF plug into the sensor.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7498.jpg[/image]


Installation complete.
[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7489.jpg[/image]

[image]http://img.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/IMG_7493.jpg[/image]


[image]http://smg.photobucket.com/albums/v673/tacobill35/KN%20CAI%20install/th_MVI_7499.jpg[/image] 

  
brian2906 -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 1:03:21 PM)

Nice install, and write up. Great pix! Thanks for the info. It should be helpfull for anyone who's doing a CAI install.

Jujudoll -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 1:17:14 PM)

I was waiting for this one.  Thanks!

thxultra -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 2:30:40 PM)

Nice directions and looks great. How is she running?

C_yru_s99 -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 2:50:05 PM)

Couldnt of found this post soon enough ! Just ordered one... Most things are self explanitory but you have made it much easier! Thanks

roothog69 -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 2:54:31 PM)

Nice write-up, I've got one for sale only 5k miles on it...PM me.(sorry to Hijack)

s2k -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 2:57:02 PM)

Hey great write-up but i only have one concern, I have heard that the K&N CAI makes you run Lean is it true?

kenthicken -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 3:27:15 PM)

Where is the heat sheild? Didn't it come with one? Mine did.

Aziraphale -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 3:58:08 PM)

quote:

ORIGINAL: kenthicken

Where is the heat sheild? Didn't it come with one? Mine did.


He said he opted not to install it originally.  Read the post  [;)]

TacoBill -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/19/2007 4:20:28 PM)

quote:

ORIGINAL: thxultra

Nice directions and looks great. How is she running?

How's she running you ask?  Like a female Banshee!!
http://www.youtube.com/watch?v=CeZ-j9po80Q



quote:

ORIGINAL: s2k

Hey great write-up but i only have one concern, I have heard that the K&N CAI makes you run Lean is it true?

I can't validate that.  Never did a dyno run with the K&N CAI so I can't say where the A/F ratio is. 

However, I'm running a custom tune from Doug and he's taken the K&N into consideration in writing my tune.



quote:

ORIGINAL: Aziraphale

quote:

ORIGINAL: kenthicken

Where is the heat sheild? Didn't it come with one? Mine did.


He said he opted not to install it originally.  Read the post  [;)]


That's correct.  I only installed the heat shield so my Shaker duct has something to attach to.  If not for the Shaker, it probably would still be off.

mygt500 -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/20/2007 3:26:48 AM)

Done this one already but great write up!

jaded seconds -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/20/2007 3:30:06 AM)

tacobill = the man. you've got great write ups. i'm going to use this guide as a semi reference. i know the install is going to be a little different. i've got jlt true cai + xcal2 coming in for my sixer.

Thurman -> RE: K&N AirCharger CAI Install (w/pics & vid) (4/20/2007 6:56:29 AM)

Nice write up!!!!

Argonaut -> RE: K&N AirCharger CAI Install (w/pics & vid) (10/15/2007 8:21:07 PM)

Hey Bill - hopefully you see this post and can reply even though its 6 months after your CAI install.  I notice in the photos that you elected to replace the stock crankcase breather hose (the one with the green PCV valve) with a piece of rubber tubing, thereby eliminating the PCV.  I know the PCV valve is one way, allowing gases to flow from the crankcase to the intake but not the other way.  I was under the impression this is important, so that you don't get air flowing the wrong way if there is ever a higher air pressure in the intake vs. the crankcase.  But in a normally aspirated engine that is probably not a big concern.  At any rate, why do the replacement?  What effect does it have on say the yearly emissions test (required where I live in PA)?  I suppose I would just put the stock unit back on for the test then remove it again.  Do you or anyone forsee any problems doing this?  Thanks.

UPDATE: my bad, now that I have pulled that stock crankcase breather hose off and examined it, I can see that it is bi-directional.  What I thought was a PCV valve (the little green valves in your photos) turns out not to be, its just a 90 degree elbow.  The reason I asked this question was, after installing a BBK CAI system, the stock breather hose would no longer reach and BBK didn't provide a replacement in their kit.  A quick trip to Pep Boys solved the problem.

rmays06 -> RE: K&N AirCharger CAI Install (w/pics & vid) (10/15/2007 8:25:54 PM)

PM him, its a better chance of him seeing this. This will be far down the list very fast.

As I type this he is lurking in this forum to answer, TACO you never disappoint....lol

quote:

ORIGINAL: Argonaut

Hey Bill - hopefully you see this post and can reply even though its 6 months after your CAI install.  I notice in the photos that you elected to replace the stock crankcase breather hose (the one with the green PCV valve) with a piece of rubber tubing, thereby eliminating the PCV.  I know the PCV valve is one way, allowing gases to flow from the crankcase to the intake but not the other way.  I was under the impression this is important, so that you don't get air flowing the wrong way if there is ever a higher air pressure in the intake vs. the crankcase.  But in a normally aspirated engine that is probably not a big concern.  At any rate, why do the replacement?  What effect does it have on say the yearly emissions test (required where I live in PA)?  I suppose I would just put the stock unit back on for the test then remove it again.  Do you or anyone forsee any problems doing this?  Thanks.

TacoBill -> RE: K&N AirCharger CAI Install (w/pics & vid) (10/15/2007 8:29:47 PM)

(I get an e/m on all new posts [8D])

The black hose was part of the K&N kit.  As far as what effects it has being bi-directional (ie. valveless), I don't know.  However, my buddy with this same K&N CAI passed emmisions here in CA.

I've sinced swapped out the K&N in favor of the C&L Racer.  This CAI also comes with an open hose.

surfbum7190 -> RE: K&N AirCharger CAI Install (w/pics & vid) (10/15/2007 8:40:00 PM)

+10000000 for this post just what i needed

TacoBill -> RE: K&N AirCharger CAI Install (w/pics & vid) (10/16/2007 7:03:46 AM)

quote:

ORIGINAL: surfbum7190

+10000000 for this post just what i needed

Just a reminder to all 07+ owners, look into that support bracket that attaches to the camcover to be sure you have the correct one.  The bracket for the 05/06 will not fit the current camcover bolt pattern.

  

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