Barry's Cold Air Intake Mod

[Barry]

I decided that after reading all this re: air intake; that there had to be a cheaper and very effective way to do this. I would only do it if it was safe and in no way effected the warranties. Well, I did it. First you disconect all the factory clamps starting from the throttle body and work your way down to the top of the air box, bear in mind to disconect the MAF sensor. Once this is done all you should see is the top of air box w/the air inlet open. Now, you will see 2 screw heads....take them out completley. Next lift the radiator hose to you left untill you see another screw...take it out as well and move the radiator hose to your right just enough where you can start to lift the top of the air box up. The filter will still be attached but you must twist the top of the box to your right and up and sideways until you can lift the entire assembly out. Now you can see the inside of the box. Next. take the top portion of the air box and unscrew the sensor. once the sensor is out, pull off the O ring by rolling it down over the sensor. Now locate the tit ( yes i said tit, now shut up and read ) where the tube connects from the top of the head to the factory air inlet hose. Just below the tit place the log part of the sensor to the hose and visualize, that is where you will be grinding a hole so that the sensor will will slide in and fit. This is trial and error and what you want is to be able to work the sensor in to where it is tight. This is the hardest part of the process. If you do it right the sensor will now fit snug over the area that you removed the O ring and will see that it is tight. Make sure of course that the arrow on the sensor is facing up in the direction of air flow. Next you may use any filter that has a cone . I bought them from Auto zone, st/st mesh.....24.95. This one was the only one that would fit into the factory air inlet tube....at the bottom of course. Once the sensor is in tight ( if your not sure use a twist tie, attach the cone filter. Make sure you clean out the oil residue and what ever shaving's are left from inside the tube. Once you done, carefully manage the filter down inside the top portion of the air box. You will need to once again move the radiator hose to you right so that the filter will drop down. As you see at his point your new filter sets at an angle. The cold air will push it's way up thru and around the new filter, while in motion the force of the air will not permit hot air into the filter and yet the box protects the filter. Befor you attach the tube to the throttle body reconnect the sensor conector and carefully reattach the oil emmision tube. Now you can attach the top of the factory air inlet to the throttle body. Check connection for fit and start car. Let it run for 5 mins. No need to disconect the battery for this. I did 4 cars in 4 hour's and no idiot light's ( service engine light) have appeared. Now Drive ! After your adventure check all for fit. To drill the the hole I used my Dremmel aprox 1-1 1/4 " diameter for the sensor. I will try to attach photo's to this thread. I was into it so much that I neglected to take pics as I went. So I do have after shot's ( if I can figuire out how to post on this forum ) When you see the pics it all look's factory from the top. This mod work's ! If I felt that this would not work...I wouldn't post it. P.S. this site says the pictures are too big....so I will post them in my gallery at Saturnfans.com Look for Barry.

[linenoyz]

I just went through your whole gallery on saturnfans...

If you want me to host them, email them.

linenoyz@linenoyz.net

[Vita]

me too, i want to see what you did with the sensor, i just cannot picture it!

[JPK]

I'd like to see some pics as well. Your gallery at SF is like 1000 pages long.

Although, it's a little too late for me, I've already destroyed my airbox while taking it completely off.

I'm still curious to see what you did though.

You can go to google and search "free JPEG resizer" and find hundreds of programs to change the pic size for free.

Also, www.IMGspot.com will host pics for free.

*edit* I see that IMGspot is down right now. I do prefer it, but you can also use this one as well http://www.afreeimagehost.com/ It's free to sign up for an account.

[Barry]

Thank's for the offer's. I've tried to email some of my pics before and outlook express almost crashed because of the size. I'll try that program for jpegs.....if I can figure it out. I'm good at some things and not others......IB Normal !

[linenoyz]

www.irfanview.com

Great freeware program that allows resizing, etc.

[Barry]

thank's guy's. I just posted them, although it only allows 5 files on this thread and there are 7 pics

[JPK]

So basically, you just got rid of the top of the airbox and use the housing to protect the filter?

[goofyguy]

Pretty much remove the lid, drilled a new hole for the Air Flow Sensor directly under the PCV port, install the sensor the correct way, secure with ziptie for a lil extra protection, attach the air filter to the tube, drop it all in. Gotta admit he did them like he was doing this for a few years. Thanks Barry.

[Aeain]

Thanks Barry, sounds like we have 2 way to do a Welfare Intake.