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1999 Acura Integra: Intake and Fuel System Upgrade A turbochcharged Integra gets a further horsepower injection with a modified intake manifold and fuel-system tweaks. From "Tricked Out" episode DTRK-409

(Continued from page 4)

Install Modified Manifold

Before he begins to install the new intake manifold, Andrew scrapes off the old gasket. If you choose to use gasket remover, be sure to stuff some old rags into the intake ports on the head so as to not get any spray inside. But be sure and remember to remove the rags before you put the new manifold on!

Placing the manifold gasket

Hooking up the throttle cable

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	Figure O
	Figure P
	Figure Q
	Figure R

• Andrew reattaches the old canister purge valve that he took off the old manifold.

• Now it's time to install the manifold. Place the intake manifold gasket on the studs on the side of the block, and then slide the new intake manifold into place (figure O). Torque down all of the nuts and bolts.

• Now you can hook everything back up. Start by replacing all of the hoses that were removed earlier.

• Plug in the fuel injector wiring harness, and hook up the throttle and transmission kick-down cables.

• Plug in the MAP sensor (figure P) and then the TPS plugs.

• Reconnect the fuel line to the fuel filter, and tighten it down (figure Q).

• Reinstall the fuel gauge.

• The coupling on the intake pipe is old and faded, so Andrew replaces it with a new one and clamps it down (figure R).

• Refill the radiator with coolant, and reattach the negative battery cable to finish up.

• Before starting the car, turn the ignition switch to run about three times to build pressure in the fuel system.

Andrew discusses the Dyno test procedures with performance specialist Chris Capiske.

Got More Power? Prove It! Take It to the Dyno!

Now that all the modifications are complete, Andrew puts the car on a Dyno for some diagnostics testing to see if all his pain will equal some real gain in the form of more power. Andrew's helped out by Chris Capiske who brings in a portable dynamometer for the testing.

• It's best to do before and after runs, and compare the charts. And before doing a full throttle Dyno run, it's a good idea to do some partial throttle tuning. Instead of going full-force and measuring peak power, keep the car's engine in a safer operating rpm to tweak the fuel curve without risking damage to the untested engine and intake combo.
  

  	The performance enhancements are put to the true test with the dynamometer.
  	Figure S

• After a few minutes testing the engine at various rpm's, Andrew decides that adjusting the fuel pressure will improve performance. After adjusting the fuel to lean out the mixture, Andrew runs the car at full-throttle once againon the Dyno. After a couple of runs, it's clear that the new intake and fuel system are improving the car's performance.

Dyno Results

As seen in the graphic results (figure S), the Dyno test showed a significant gain of about 20 horsepower below 4000 rpm, but the Integra then lost about ten of those horses between 4500 and 6000 rpm — likely due mainly to the power-robbing automatic transmission. At the top end, our peak horsepower saw a modest bump from 155 to 172 at 6500 RPM.

It'll take some more work to bring the high-rpm range to the point where the new intake and fuel system will truly shine, but the increased low end torque will definitely make the car more fun to drive around town. And an overall gain of 17 horsepower is nothing to sneeze at.

The Bottom Line:

intake manifold $200
gaskets $20
aluminum fuel rail $140
fuel pressure regulator $ 220

Total = $680

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RESOURCES :

Special resources for DIY's Tricked Out 400 series

Racing Innovations
www.racinginnovations.com

Knoxville Dragway
www.knoxdragway.com

Wetherill Associates
www.waipowdercoating.com

SPC Performance
www.spcperformance.com

AEM
www.aempower.com

Kicker
www.kicker.com

Autoloc
www.thehoffmangroup.com

Killer Cans by Alsa Corp.
www.alsacorp.com

Rapido Group
www.rapidogroup.com

Stellar Security
www.thehoffmangroup.com

Dyno Dynamics
www.dynodynamics.com

Stillen
www.stillen.com

Skunk2 Racing
www.skunk2.com

Injen Technologies
www.injen.com

Nitrous Express
www.nitrousexpress.com

Synapse Engineering
www.synapseengineering.com

Air Ride Technologies
www.ridetech.com

Airgasm Kustomz
www.airgasmkustomz.com

Lincoln Electric
www.lincolnelectric.com

Mickey Thompson Performance Tires And Wheels
www.mickeythompsontires.com

Buggies Unlimited
www.buggiesunlimited.com

GUESTS :

Chris Capiske
Dyno Dynamics
www.dynodynamics.com