DannyboyDS
Just hand me the pliers.
- Joined
- Feb 26, 2007
- Messages
- 2,255
- Reaction score
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- Age
- 39
- Location
- Melbourne
- Members Ride
- VS Berlina
Okay so here is how I did it.
Firstly I would like to say that if you do this I cannot promise it is legal, will work, wont stuff things, blah blah.
Tools needed.
Drill
Socket Set (Cant remember sizes)
Knife
Hack Saw
File/rasp
screw driver set
alan keys
Materials
1 X Extra Panel Filter Box $30 from wreckers
1 X CAI $60 from Holden
1 X CAI to Filter box joiner $15 from Holden
1 X CAI mount screws $5 from Holden
1 X 90 degree air inlet pipe $10 Autobarn
1 X fiber glass repair kit $24 Autobarn
1 X pod filter $35 (Depends on what you want, I Bought a cheapy)
Step one
Remove the old air box, the whole thing, leave the plenum pipe though, no need to change this
unless you have a fully sick one you REALLY want in there.
all you need to do to do this is undo the hose clamp on the plenum pipe, then undo the clips on
the airbox, open it, remove the filter adn undo the three nuts on the bottom on this inside.
oh and remember to unplug the wires connected to the airbox if there are any, we will worry about retrieving that part later.
Step two
keep the removed airbox and filter just incase and grab your newer one, rip off the dicky little
snorkal thing from the front on the bottom half of the airbox and drop kick it, now you will need
to cut the hole a bit to fit the airbox to CAI joiner, match it up, mark it and cut it, do this
bit by bit if you want and you have less chances of making a mistake.
Step three
Grab the top half of the new airbox and start making that hole a bit bigger, remember to remove
the old plenum pipe joiner first, from the inside and the out, you will need the alan keys here.
Fit the 90 degree pipe, keep working at it slowly untill you can get the pipe in on an angle
that allows the pod filter to be fitted, remember you will need to remove and reinstall the pod
filter at times.
I actually had to cut my pipe a bit shorter because the plenum pipe wouldnt quite fit otherwise, just wouldnt squash the way I wanted it too.
Step four
Line everything up on the top half of the airbox, fibre glass it shut, once the fibre glas has
set you can spray it black too if you like, I sprayed mine and the pipe and even my engine cover.
Step five
Remove the air temp sensor from the old airbox IF ONE WAS ATTACHED.
it will have been on the back of the top half, remeber those wires? if not then you dont need to
do this, if so well then this is easy anyway.
grab a flathead screwdriver, look inside the airbox, push the flat head under the little metal
ring holding the sensor and turn slightly, do this a afew times and it will pop off.
Step six
Grab the new airbox top half and drill a hole for the air temp sensor, push it in so the plug is
on the outside, take the metal ring and push it on from the inside of the box, walla its fitted.
Step Seven
screw the new airbox bottom half down, remember those three nuts?
drop the top half down and snap it on there, then connect the plenum pipe and tighten up that
hose clamp.
fit the airbox to CAI joiner to the front, atm it will look kind of useless aye
grab the CAI and sit it on top of the radiator housing, I lined mine up perfectly square with it
as best I could by eye, and never had any dramas.
Drill three holes, being sure nto to drill too far, just the housing will suffice, push your holden screws in.
I cant remember the drill bit size either, im fairly useless tbh.
oh nice oh rice
P.S remove the 20 amp engine fuse for a few moments to reset the computer. will allow it to adjust to its new air intake a little better, or so im led to believe.
Image Index
Image 1 - I had to cut the bloody pipe
Image 2 - Expand the hole
Image 3 - Air temp sensor
Image 4 - CAI
Image 5 - The Pod in the box
Image 6 - The only usefull pic
Firstly I would like to say that if you do this I cannot promise it is legal, will work, wont stuff things, blah blah.
Tools needed.
Drill
Socket Set (Cant remember sizes)
Knife
Hack Saw
File/rasp
screw driver set
alan keys
Materials
1 X Extra Panel Filter Box $30 from wreckers
1 X CAI $60 from Holden
1 X CAI to Filter box joiner $15 from Holden
1 X CAI mount screws $5 from Holden
1 X 90 degree air inlet pipe $10 Autobarn
1 X fiber glass repair kit $24 Autobarn
1 X pod filter $35 (Depends on what you want, I Bought a cheapy)
Step one
Remove the old air box, the whole thing, leave the plenum pipe though, no need to change this
unless you have a fully sick one you REALLY want in there.
all you need to do to do this is undo the hose clamp on the plenum pipe, then undo the clips on
the airbox, open it, remove the filter adn undo the three nuts on the bottom on this inside.
oh and remember to unplug the wires connected to the airbox if there are any, we will worry about retrieving that part later.
Step two
keep the removed airbox and filter just incase and grab your newer one, rip off the dicky little
snorkal thing from the front on the bottom half of the airbox and drop kick it, now you will need
to cut the hole a bit to fit the airbox to CAI joiner, match it up, mark it and cut it, do this
bit by bit if you want and you have less chances of making a mistake.
Step three
Grab the top half of the new airbox and start making that hole a bit bigger, remember to remove
the old plenum pipe joiner first, from the inside and the out, you will need the alan keys here.
Fit the 90 degree pipe, keep working at it slowly untill you can get the pipe in on an angle
that allows the pod filter to be fitted, remember you will need to remove and reinstall the pod
filter at times.
I actually had to cut my pipe a bit shorter because the plenum pipe wouldnt quite fit otherwise, just wouldnt squash the way I wanted it too.
Step four
Line everything up on the top half of the airbox, fibre glass it shut, once the fibre glas has
set you can spray it black too if you like, I sprayed mine and the pipe and even my engine cover.
Step five
Remove the air temp sensor from the old airbox IF ONE WAS ATTACHED.
it will have been on the back of the top half, remeber those wires? if not then you dont need to
do this, if so well then this is easy anyway.
grab a flathead screwdriver, look inside the airbox, push the flat head under the little metal
ring holding the sensor and turn slightly, do this a afew times and it will pop off.
Step six
Grab the new airbox top half and drill a hole for the air temp sensor, push it in so the plug is
on the outside, take the metal ring and push it on from the inside of the box, walla its fitted.
Step Seven
screw the new airbox bottom half down, remember those three nuts?
drop the top half down and snap it on there, then connect the plenum pipe and tighten up that
hose clamp.
fit the airbox to CAI joiner to the front, atm it will look kind of useless aye
grab the CAI and sit it on top of the radiator housing, I lined mine up perfectly square with it
as best I could by eye, and never had any dramas.
Drill three holes, being sure nto to drill too far, just the housing will suffice, push your holden screws in.
I cant remember the drill bit size either, im fairly useless tbh.
oh nice oh rice
P.S remove the 20 amp engine fuse for a few moments to reset the computer. will allow it to adjust to its new air intake a little better, or so im led to believe.
Image Index
Image 1 - I had to cut the bloody pipe
Image 2 - Expand the hole
Image 3 - Air temp sensor
Image 4 - CAI
Image 5 - The Pod in the box
Image 6 - The only usefull pic
Attachments
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