- You current upper IC piping will need to be modified or re-done to fit the sheetmetal intake manifold. In the future we will offer a custom upper pipe
that will work with our manifolds.
- Your upper radiator hose will need to be removed and slightly trimmed so it may be a good idea to drain the coolant and remove the hose before you start anything.
- Remove all of the obvious things connecting to the intake manifold, vacuum lines, intercooler piping, throttle body, wiring etc.
- There are (5) 10mm bolts holding the intake manifold onto the head, and (1) hard to reach 17mm bolt that ties a bracket into the neck of the stock intake manifold.
- Once the manifold is removed, you will have access to the fitting coming out of the t-stat housing that needs to be replaced, supplied with the intake manifold is
a new piece of heater hose, a new brass fitting, and clamps to go along with it.
- Remove the old hose clamps, old piece of hose, and the silver fitting(if you didn't drain the coolant enough more will come out at this point). Then replace the silver water hose fitting with
the new 3/8" NPT brass 45° fitting, a pair of vise grips, or a pipe wrench will work best to get the old fitting out. It needs to be removed
or else it will rub on the runner of the new intake manifold. See picture below:
- After the new brass fitting is in place and tightened up, spray some WD40 into the new piece of hose so it will slide over the new fittings easily. Install the new hose and slide it up high enough on the brass fitting
so that it does not kink at the bend. Install and tighten the hose clamps. See pictures below:
- Next you will need to modify the dipstick mounting bracket a bit, due to the shorter runner length the bracket is too long and needs to be bent in the shape of a "U" or "V". This is much easier to
do once the dipstick is removed, if you have a hard time getting it out don't force it, you can still bend the bracket in place, it will just be a lot harder to slide the new intake manifold over the dipstick if it
is already in place. See pictures below:
- Next decide if it will be easier for you to install the injectors and fuel rail now, or once the intake is installed on the car. We found both ways took about the same amount of time. The injector holes are machined to a
precise .530" bore which is the standard for injectors. The holes have a very tight clearance to make sure the no air leaks out so installing the injectors might be a little tricky. We do
not recommend lubricating the injector O-rings, this tends to cause the injector to actually slip out of the O-ring when force is applied. The best way is to install them dry, and wiggle the injectors into a
circular motion until the bottom out and cant go in any further. Supplied with your intake manifold are 2 different size plastic bushings
designed to go between the mounts on your fuel rail, and the mounts on the intake manifold. These spacers will eliminate vibration
of your fuel rail. The supplied spacers will work with most setups, however different brand injectors and fuel rails all have different
dimensions. It may be neccessary to add a few washers on top of the bushings to fill in the gap.
- Before installing the intake manifold clean the cylinder head surface with a scotch brite or sandpaper to remove and dirt or oil that will cause the gasket to not seal properly.
- It is important that you replace your gasket with a new one, its even better to spray both sides of the gasket with a spray RTV sealant.
- Install the new intake manifold, then torque all bolts to factory specs. If you removed the dipstick reinstall it now. Hook up all your vacuum lines and reinstall everything else in reverse order.
- Due to the larger plenum of the sheetmetal intake it may or may not rub the upper radiator hose by the throttle body if flange. If it doesn't then continue on with reinstalling everything, if it does there is
an easy fix. Luckily there is some extra straight length that can be trimmed back. Typical cut length is anywhere from 1" to 2", take off a little bit at a time until it fits just right. Make sure you don't take off
too much! See pictures below:
- If you find that the wiring harnesses for the throttle body sensors are very tight, you can free up some slack by cutting away some of the electrical tape, pulling back the wires, and re-taping them.
- Once the upper radiator hose is installed, fill the car up with coolant and check for leaks. Fire up the car and check or listen for any boost leaks. If everything checks out, hit the streets and have some fun!
- If you have any questions at all please don't hesitate to call or email us!
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