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Canadas FarEast Profile
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Date Registered: 10-2005
Location: Newfoundland Canada
TOTAL POSTS: 395
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Re: Air intake design


quote:

jalalski wrote:

I may need your help again here mate if you don't mind, but I will take this off-line and chat to you whenever you're on Messenger next time.



MSN not working for me - - shoot me an e-mail (you have my address).

Cheers = Roger



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Roger
X 228


2006 X-T Bonavista Edition
Production Number 0001

25/Aug/2006, 3:18 am Link to this post Send Email PM   Send Private Message
 
jalalski Profile
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
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Re: Air intake design


Hi Guys,

I finally made my decision after over 3 years of not being sure what to do about getting a CAI emoticon

This mod has always been on the back of my mind, so I decided to go a head with it. (finally)

The Cosmo Racing CAI is on its way to me BUT I have also ordered the bypass valve so I can test fit it with the CAI set-up and see if it fits.

Once I get the CAI fitted, I will do some test runs with it and record the impact on fuel and power and report back.

Once that has been done, I have something else in mind which I can't disclose now emoticon

I would like to thank Roger for never giving-up on me and encouraging me to go a head with this mod. I always needed that final and most important push. hehehehe

Stay tuned for the next "power update"



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1/Sep/2006, 11:02 pm Link to this post Send Private Message MSN Blog
 
BRETT72 Profile
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X-TRAIL HOLIC
 


Date Registered: 10-2005
Location: Orange. NSW.
TOTAL POSTS: 1999
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Re: Air intake design


 I will be eagerly awaiting your analysis mate. The CAI is also on the cards, depending on the bypass working.

 Am I expecting to see the 'chrome warrior' at Summernats soon. emoticon


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BRETT72 - X235

2/Sep/2006, 8:07 pm Link to this post Send Email PM   Send Private Message MSN
 
jalalski Profile
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
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CAI & Bypass Valve Installed


Hi Guys,

The project of installing the Cosmo Racing CAI and AEM Bypass Valve started at 8am this morning. The weather was perfect for it. emoticon

Already planned a head how and where am gonna fit the bypass valve, but it was a matter of putting the ideas into practice and see if it actually fits.

Started removing the stock plastic intake, hoses and the air filter box and hit a problem. The Cosmo Racing CAI DIY Guide which is prepared by Ryan from the NissanForums suggested that there 2 bolts holding the air filter box in place, finding the first one was easy, but I spent the next hour or so trying to find the second bolt and I couldn't.

At the end and because I was desperate to finish this install today, I decided to remove the 2 bolts that were securing the mounting bracket of the filter box and man what a task that was.

Removing these two bolts took me about 2 hours cause I just couldn't get to them easily and had to remove the battery too.

2 hours later it was out, by that time my back was hurting like hell, my hands full of scratches and the next door neighbor could hear me swearing my head off and thought am gonna smash the exy to pieces LOL emoticon

Image

Taking out the resonator box in the front section of the fender was very easy and this has completed the removal process of the factory filter and intake.

Now it was time to install the CAI and I started at the throttle body and worked my way down until I got to the section where I fitted the AEM bypass valve and another small problem, the mounting points of the pipes no longer matched the holes in the body of the car where it should be mounted.

Very luckily for me and after I fiddled with the lower portion of the pipe, I managed to align it with 2 new mounting points and secured it properly in place using the rubber mounts and washers.

This is how it looked with the battery taken off.

Image Image Image

Now it was time to fit the battery back and see if that bypass valve would clear it and luckily it did only just.

Image Image

After that, it was time to fit the cone filter where the factory resonator box once lived.

Image

One thing none of the guys who installed a CAI mentioned was a breather hose I found attached to the base of the factory filter box

Image

I secured this breather hose with a cable tie as high as I could.

Image Image

Plugged in the MAF sensor harness and turned on the engine and WOW! what an awesome sound indeed.

Revved it up as hard as I can and my son came out running from the house saying that it sounds so cool LOL emoticon

Put everything back in place, the splash guard and the left wheel which I have taken off earlier and this is the end result.

Image Image Image

Took it for a test drive and what can I say...mate, bring on that GT and lets see if it can match my exy. hahahaha emoticon

Amazing is a good word to describe it and the acceleration has improved considerably to what I already had in terms of power with the Hi-Tech system.

Not sure if it's just my imagination but I felt that even idling was MUCH smoother than before.

All that and I haven't even re-set the ECU, so am expecting it to get even better when I reset the ECU tomorrow.

I believe this is the first time an exy was fitted with a CAI and Bypass valve and the project is a success.

Worth considering for those of you KW/HP seekers and money well spent.

I am extremely happy with the performance, the looks and the sound of it emoticon

BTW: I finished at 2pm emoticon



Last edited by jalalski, 11/Oct/2009, 7:42 am


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8/Oct/2006, 12:59 am Link to this post Send Private Message MSN Blog
 
basshead Profile
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X-TRAIL HOLIC
 


Date Registered: 02-2004
Location: Panania, Sydney
TOTAL POSTS: 2852
Reply | QUOTE
Re: CAI & Bypass Valve Installed


quote:

jalalski wrote:

I believe this is the first time an exy was fitted with a CAI and Bypass valve and the project is a success.



Ah, but will you test it by doing a creek-crossing? emoticon

quote:


Worth considering for those of you KW/HP seekers and money well spent.



I wonder if it would make as much of a difference to a completely stock engine. Once the ECU has fully adjusted, you'll have to get it dyno'ed so we all know exactly what sort of increase is achievable with the Cosmo Racing CIA!

Excellent job and it really does look like a professional install; good enough to be a factory option!

You've done just about everything you can outside the engine - you'll be doing headwork and cams before you know it! emoticon LOL!


---
Rich. X-013(c)
'04 S2 ST Auto. Nudge_roofracks_tow_tints_Lightforce_GME_YokoGeoA/T-S_TBS_bashplate_50mm-spacer-lift
Click here to see >300MB of photos and videos All For His Glory.
8/Oct/2006, 2:08 am Link to this post Send Email PM   Send Private Message MSN Yahoo Blog
 
BRETT72 Profile
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X-TRAIL HOLIC
 


Date Registered: 10-2005
Location: Orange. NSW.
TOTAL POSTS: 1999
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Re: Air intake design & modifications


 Congrats Jalal on 'completing' another phase of your dream exy. I am very interested to see what sort of 0-100kph times you can run now. Will I be seeing you run the 1/4 mile at Eastern Creek soon ???
The CAI looks excellent, well done.

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BRETT72 - X235

8/Oct/2006, 6:47 am Link to this post Send Email PM   Send Private Message MSN
 
jalalski Profile
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
Reply | QUOTE
Re: CAI & Bypass Valve Installed


quote:

basshead wrote:
Ah, but will you test it by doing a creek-crossing? emoticon



If a creek crossing happens to be in my run from home to work, then I'll do it, otherwise I see no reason to intentionally submerge my exy just to prove what has already been done and tested in regards to the bypass valve. I don't want to get my 18" alloys dirty emoticon

The bypass valve is a preventative measure, it doesn't mean that it will allow you to do creek crossing safely and will NOT substitute a snorkel.

quote:


I wonder if it would make as much of a difference to a completely stock engine. Once the ECU has fully adjusted, you'll have to get it dyno'ed so we all know exactly what sort of increase is achievable with the Cosmo Racing CAI!



It should in theory Rich, you're giving your engine a doze of cold air at a much higher ratio, this would improve power and it should also improve fuel consumption (am gonna monitor that) except one slight problem, you'll be hooked into flying off from the lights. hahaha emoticon

quote:

You've done just about everything you can outside the engine - you'll be doing headwork and cams before you know it! emoticon LOL!



Next mod is an engine related one, where am gonna remove the balancer shafts (more on this mod later in a separate topic)

Brett: Yep, I'll do the 0-100kms soon and let you guy know. As for Eastern Creek, everything is possible LOL



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8/Oct/2006, 9:06 am Link to this post Send Private Message MSN Blog
 
Canadas FarEast Profile
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Date Registered: 10-2005
Location: Newfoundland Canada
TOTAL POSTS: 395
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Re: Air intake design & modifications


Jalal:

Sorry I was not on-line to help emoticon

Got your email - replied - visited the forum and saw that you had reached Mission Accomplished - good for you.

Knew you'd love this mod emoticon

Much as you love the sound now - wait until you kick down to pass someone on the highway - WOW is not the word emoticon

BTW - don't bother to monitor fuel consumption until your foot becomes about 3 kgs lighter - which will probably take weeks or months emoticon

Enjoy = Roger

Last edited by Canadas FarEast, 8/Oct/2006, 9:50 am


---
Roger
X 228


2006 X-T Bonavista Edition
Production Number 0001

8/Oct/2006, 9:39 am Link to this post Send Email PM   Send Private Message
 
jalalski Profile
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
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Re: Air intake design & modifications


Roger,

I was so STUCK with this part of the install that I just wanted to ask someone what to do and had I known your phone number, I would have called you in the middle of the night. I actually sent you the email and posted the question on NF when I saw you on line, but I must have just missed you and Valboo replied about 10 minutes too late when I started removing the damn 2 bolts from that bracket and got a back injury doing so LOL

Yeah, knowing myself and the fun I am still having with the Hi-Tech system almost a year later from when I installed it, the outlook of better fuel economy with the CAI is looking less likely emoticon

Roger: One question, is the supplied with kit filter ready to be used, or does it need oiling? It didn't look oily to me when I installed it.

Last edited by jalalski, 8/Oct/2006, 9:51 am


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8/Oct/2006, 9:48 am Link to this post Send Private Message MSN Blog
 
Canadas FarEast Profile
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BANNED USER

Date Registered: 10-2005
Location: Newfoundland Canada
TOTAL POSTS: 395
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Re: Air intake design & modifications


They claim that these CAI systems will increase HP anywhere from to 6 to 12...

Don't know the actual gain, but in my experience, there was most definitely an increase in Hp, especially from a standing start and when passing on the highway...

I also noted an improvement in the "smoothness" of the engine at idle.

Don't know if it would help any, but it looks like you could shorten up the vacuum line by about 8 or 10 inches - - I cut the one that came with mine so it ran in a fairly straight line....

Cheers = Roger

---
Roger
X 228


2006 X-T Bonavista Edition
Production Number 0001

8/Oct/2006, 9:59 am Link to this post Send Email PM   Send Private Message
 


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