DIY Network

Performance Add-Ons: Cold-Air Intake From "Weekend Mechanic" episode WKM-307

	The factory air-intake system consists of the air-cleaner element and housing and the air-duct hose.
	The cold-air intake and filter routes air from beneath the car and results in increased horsepower and torque since the air coming into the engine is cooler.

In this segment of DIY's Weekend Mechanic, host Bruce Bonebrake installs a cold-air intake on the Acura. With the fiberglass body parts out being professionally repainted, it's a convenient time for us to do this relatively simple upgrade on the car's engine for increased horsepower. The cold-air intake that we installed only cost about $185.

Note: Replacing the standard (OEM) air-intake with a kit like this may change the way the engine sounds.

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), some of the specialty tools and materials used in this episode include a fiberglass ground effects kit, cold-air intake system with air filter and carbon-fiber laminate hood. An air-compressor and set of pneumatic tools (including a grinding wheel) is optional, but will be helpful for this project.

DIY Difficulty Rating for the Repair: This job is relatively straightforward, and requires little in the way of specialty tools. It should be easily within reach for most automotive do-it-yourselfers. We gave it a difficulty rating of 2 on a 5-point intermediate-level scale.

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Installing a Cold-Air Intake

• Unbolt the air-intake housing using the appropriate socket (figure A).

• Remove the crank-case manifold hose-clamps.

• Remove the clamps from the existing air-cleaner hose.

• Remove the manifold breather pipe from the side of the hose (figure B).

  Figure B

  Figure A

  
  

• With the hoses disconnected, carefully lift out the air-cleaner housing (figure C).

  Remove the resonator -- i.e., the air collection duct for the air-cleaner -- that is located behind the headlight (figure D).

  Figure C

  Figure D

  
  

• With the original air-cleaner assembly removed from the car, some hoses, brackets and covers will need to be removed or moved out of the way to make installation of the new unit possible. Follow the manufacturer's instructions that come with the cold-air intake kit. In our case, the kit we installed was not a universal part, but was specifically designed for this vehicle. The instructions detailed exactly which parts needed to be removed or relocated.

  Unbolt and remove the body corner-bracket from behind the battery (figure E).

  Unbolt the ABS connector (figure F) and set it out of the way.

  Figure E

  Figure F

  
  

• Bolt the air-intake pipe-mount in place according to the manufacturer's directions.

• Position the new air-intake pipe in place (figure G) and secure it. The air-filter will be mounted behind the bumper.

  Once the new intake pipe is bolted in position, install the hoses and clamps. A short, flexible hose is inserted between the air-intake pipe and throttle body. Push the hose onto each part far enough to provide room to clamp each end(figure H).

  Figure G

  Figure H

  
  

  	Figure J
  	Figure I

• Two lines needed to be modified -- the line for the crank-case ventilation that leads into the valve cover, and the coolant-bypass line (figure I). The factory line assembly gets removed and replaced with two rubber hoses.

  Connect the manifold breather pipe to the new air-intake pipe.

  Re-install the ABS connector and secure it in place.

  Before remove the coolant bypass pipes, drain the coolant from the car. On our Acura, the drain valve at the bottom of the radiator is opened, and the fluid is allowed to drain out into a drain pan.

  Safety Alert: Always dispose of automotive fluids (antifreeze, motor oil, transmission fluid, etc.) and other toxic substances responsibly. Most auto center offer recycling of automotive fluids.

  Next, remove the crank-case ventilation hose from the valve cover, and disconnect the coolant bypass hose (figure J). Unclamp both hoses and remove them from the car.
  

  Figure L

  Figure K

• Install the new crank-case ventilation hose (figure K).

  Install the new coolant bypass hose (figure L), clamping it securely at both ends.
  

• Secure the air-intake hose by tightening down the pipe clamps (figure M) on each end of the hose.

  With the new intake pipe installed, re-fill the radiator with coolant (figure N)

  Figure N

  Figure M

  
  

• The only thing left to do for this installation is to place the filter on the front end of the new air-intake (figures O and P), and crank up the engine for a test run.

  Figure O

  Figure P

  
  

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 ear protection, and follow proper safety precautions, when working with power tools and pneumatic tools. Also wear eye protection any time that you are working beneath a vehicle.

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 :

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896

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