VZ SV6 DIY Cold Air Intake (how to step by step instructions)

[OS-Mike]

So i made a cold air intake for my car and a few people asked me to make a step by step how to all up it cost me $45 and took 3-4 hours.



Parts required.
1. Pod filter i recommend Simota part number JAU-F02201-05 (84mm inside diameter) found here Untitled Document

2. A pice of alloy about 100x50cm i used 1.2mm thick so it was easy to bend.

3. An old door seal or something similar.

4. A box of beer use box to make template and drink beer while making CAI.

5. 2x nuts and bolts to attach the MAF sensor to the shroud.

Tools required.
From memory the tools i used- Air hacksaw (im lazy) normal one would work fine, Hole saw around 87mm, Screw drivers, 7mm spanner or socket, Side cutters,Hammer, file, Torx bit to remove standard air box (i removed it with a crow bar without breaking it i didnt have torx bit set at home)

Step 1.
Remove Airbox (blue outline) and maf sensor (green outline) bottom half of airbox is held in by torx bits but its possible to just pry it off with a crow bar if you dont have torx bits. Remove maf sensor from top half of airbox 7mm bolts from memory.



Step 2.
Make a cardboard template.







Step 3.
Remove radiator cover (red outline), L/H engine cover (yellow outline), Template and maf sensor.

Step 4.
Making heat shroud use a vivid (texter) and draw around template onto alloy then cut out and drill holes to make the bends i used two pices of wood to hold alloy in a vice then hammered it into shape. Note* these measurements are in millimetres and are rough and may not be exact.













Step 5.
You will need to cut some slots into the bottom to clear air-con pipe, abs sensor cable and chassis rail these slots can be seen in the photos above also you need to trim a pice of the bottom L/H side of the radiator cover.



Step 6.
Once the shroud fits in nicely remove it and attach the maf sensor to the shroud.



Step 7.
Cut some pices of door seal to go around the top where it seals against the bonnet (the bonnet actually holds it in place) and where it seals on the strut tower.





Step 8.
Fit the shroud into place this bit can be a little tricky then fit the filter to the end of the MAF sensor and refit engine cover and radiator cover.

Final result
After these pics were taken i had to remove it and trim a bit off by the strut tower to make it fit properly so there is no gap on the side.





Dyno run after i finished (sorry no before run to compare) only other modification is removed rear muffler.





Hope you like it just took me 2 hours to make this post

[OS-Mike]

Almost forgot there is some induction noise but nothing like the 3.8v6 or the v8s probly due to the intake manifold design and i also plan on changing the pipe between MAF and throttle body to a silicon elbow from throttle body to a pice of alloy pipe and a silicon joiner to maf sensor.

More pics here aswell if this link works http://s289.photobucket.com/albums/l...afilter=images

[HERONVY]

Excellent write up!!

Looks good too in the foldable ally, would look that much better high polished or chrome *jizz* lol

Massive thumbs up to you mate

Al

Sent from my X10i using Tapatalk

[mtharv]

Sensational write up mate, il be attempting this over the up coming weekend
Cheers man

[MY VZ]

does it seal on the top? wouldnt any cold air get mixed with hot air from under the hood?

[OS-Mike]

yea it seals when i shut the bonnet its not air tight or anything but its enough to keep the hot air out after a 4 hour drive i popped the bonnet to see how it was working engine side warm to touch inside was cool to touch.