DIY Network

Toyota Matrix: Short-Ram Air-Intake and Piggyback ECU From "Tricked Out" episode DTRK-102

The short-ram air intake provides enhanced fuel-air mix. For even more power, you might consider a turbocharger and intercooler.

In this segment of Tricked Out the suspension work continues on the Toyota Matrix with the assembly and installation of a short-ram air intake and a "piggyback" engine-control unit.

DIY Difficulty Rating for Repair: This computer and exhaust project is fairly straightforward in terms of installation. We gave it a difficulty rating of 2 on a 5-point intermediate-level scale. All of the modifications simply bolt on or plug in.

Materials needed:

This product requires only the kits and parts installed, and standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.). An air-compressor and set of pneumatic tools is optional, but may help speed the assembly process.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

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Short-Ram Air Intake

• With the original air-intake system removed (figure A), the mass air-flow sensor from the old air-box needs to be transferred to the new inlet pipe. The mass air-flow sensor serves to meter the amount of gas that goes into the engine. Removing it from the old box simply requires removing some small Phillips-head screws.

• Secure the sensor to the new pipe using the 4mm hex-bolts that were supplied with the kit (figure B). Also be certain to secure the filter and coupling to each end of the pipe, following the manufacturer's instructions. Also, before installing the new intake onto the car, check to be sure that the inside of the pipe is free of any debris, metal shavings, packing material, etc. Once it is installed, any impurities left in the pipe will ultimately get sucked into the engine, and may cause serious problems.

  Figure A

  Figure B

  
  
• Once the sensor is secured in place, to install the short-ram intake, slide the assembly onto the throttle body and work it into position (figure C).

• From underneath the filter end, attach the intake tube to the C-bracket using a 6mm hex bolt (figure D). At the other end of the C-bracket, tighten the nut that was left loose earlier for adjustment.

  Figure C

  Figure D

  
  
• Tighten the hose clamps at the throttle body (figure E).

• Attach the evap OBD canister hose to the nipple on the intake as shown (figure F).

  Figure E

  Figure F

  
  
• You're almost done. Simply plug in the mass air-flow sensor (figure G).

• Now, replace the engine cover (figure H), and the short-ram installation is complete.

  Figure G

  Figure H

  
  

  The Uni-chip engine control unit (ECU) boosts power and improves fuel efficiency. And because it's custom-programmable, it's a building block for later enhancements and modifications.

The new piggyback engine-control unit (ECU) is an easy 2-bolt, plug-in installation that works ideally with the new air-intake and exhaust system to help boost power even more. This particular unit is known as the Unichip -- but it's more than just an ordinary chip. It's a computerized modification that optimizes fuel and ignition curves to make use of improved airflow. The particular Unichip we installed was actually pre-programmed for the Toyota Matrix model featured in this episode.

"Not only is it going to work with the new air intake system and the new exhaust mods," says automotive expert Harry McKinney, "but it's going to increase horsepower as it works with both. It's so close to a standalone ECU that it can change more than 53,000 different parameters on the car." The unit is also re-programmable for other vehicles and specifications. "That's the great thing about it," says MckKinney, "It's a building block for things to come.

• Starting with an empty glove-box, squeeze the side-walls to release the stop-tabs (figure I) so that you can remove the glove box by lifting it up and out of its hinges.

• The ECU cover-panel is held in place by push-in plastic fasteners. These can be popped out by applying pressure behind the panel, or pried out using a standard screwdriver. With the panel out of the way, unscrew the ECU mounting bolts through the glove-box opening using a Phillips-head screwdriver (figure J).

  Figure I

  Figure J

  
  
• Drop the ECU down (figure K) and unplug the four wiring-harness connectors from the back of the unit. Remove the factory ECU. The new piggyback unit can be installed at the workbench.

• Following the manufacturer's instructions, make the wiring-harness connections to connect the new unit to the ECU. With our unit, the plug-in procedure is fairly idiot-proof since the plugs and ports are made so they can only fit together one way -- the right way. The same thing applies to the factory harness (figure L).

  Figure K

  Figure L

  
  
• The only thing left to do is secure the new control unit and plug it in. Plug in the piggyback unit and reinstall the ECU (with the new piggyback addition) the same way it came out. Work it up into position behind the glove-box (figure M). Replace and tighten the securing screws. Secure the piggyback unit up, and out of the way, by wrapping a wire-tie around the factory wiring harness and through the mounting hole in the unit.

• With all of the components connected and secured in position, reposition the ECU cover panel and lock it down with the plastic fasteners. Reinstall the glove-box (figure N), and the new ECU installation is complete.

  Figure M

  Figure N

  
  

Important: Included in this segment are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools or pneumatic tools.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Toyota Performance Handbook (Motorbooks International Performance Handbook Series)
Author: Pat Braden
Publisher: Motorbooks International
May 1990 ASIN: 0879383208
To order this book from Amazon.com, click here.

Supercharging, Turbocharging, & Nitrous Oxide Performance Handbook (Powerpro)
by Earl Davis, Diane Davis
Motorbooks International
December, 2001
ISBN: 0760308373
To order this book from Amazon.com, click here.