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CAI & Bypass Valve Installed
The project of installing the Cosmo Racing CAI and AEM Bypass Valve started at 8am this morning. The weather was perfect for it.
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
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.
Now it was time to fit the battery back and see if that bypass valve would clear it and luckily it did only just.
After that, it was time to fit the cone filter where the factory resonator box once lived.
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
I secured this breather hose with a cable tie as high as I could.
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
Put everything back in place, the splash guard and the left wheel which I have taken off earlier and this is the end result.
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
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
BTW: I finished at 2pm
Last edited by jalalski, 11/Oct/2009, 7:42 am
8/Oct/2006, 12:59 am
Re: CAI & Bypass Valve Installed
Ah, but will you test it by doing a creek-crossing?
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
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.
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
You've done just about everything you can outside the engine - you'll be doing headwork and cams before you know it! 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
8/Oct/2006, 9:06 am
Re: Air intake design & modifications
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
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
8/Oct/2006, 9:48 am
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