In this how to you will see the process of installing KarKraft's intake manifold spacer kit on my 01' cobra. The whole install took about 45 minutes and should be done once the engine has cooled. this install is very straight forward and simple, remember to disconect vehicle battery to reset pcm fuel learn tables.
Link to dyno graph gains tested on my vehicle:
http://i237.photobucket.com/albums/ff277/drewsfbpsi/scan0002.jpg
Tools required:
3/8" ratchet
1/4" ratchet
8mm 1/4" deep socket
10mm 1/4" deep socket
10mm 3/8" deep socket
flathead screwdriver
7mm boxed in wrench
razor blade
3m scuffpad
rags
brake clean
*** recommend new EGR gasket, But not Required***
In these pics my spacer was already installed but will show the process and steps taken to perform modification.
loosen up the 2 8mm worm clamps and disconnect Iat sensor to move intake tube out of the way.
To disconnect the cruise cable, it will unclip upwards, for the throttle cable open throttle body by rotating back and use throttle cable slack to allow cable to fit through slotted portion.
With throttle cable disconnected, unhook the spring connecting the throttle body to cable bracket.
Remove the 2 8mm bolts mounting the bracket to the upper manifold and pull up on the hold bracket for the 2 cables to release it off the 8mm intake stud.
Once unbolted and all cables released place assembly to the side.
Next remove the vacuum line connected to the lower portion off the upper manifold located on the IAC side. Also disconnect the IAC and TPS sensor connectors.
On the driver side of the manifold you will disconnect the rubber hose located next to the EGR solenoid unit, and use the 7mm socket and ratchet to remove the 2 bolts that attach that unit to the manifold.
Use a flatblade screwdriver to pry up on the vacuum line fitting
On the back of the manifold is the DPFE sensor which is held in place by 2 7mm bolts, be careful when removing by hand as to not drop these.
Remove the vacuum line from top of EGR valve to give the rest of the rest of the lines slack. use the 3/8" ratchet and 10mm socket to crack the EGR bolts loose and remove.
Here is the pic with everything removed, all the factory bolts are 8mm blots, loosen and remove all bolts.
Once all bolts are removed, pull up and slide out from under EGR valve
With the upper manifold off use the 3m scuff pad and razor blade to clean up the sealing surface.
At this time use a razor blade and scuffpad to remove any gasket material from EGR mounting port.
Take care when removing old gasket if not purchasing a new one to not cut the seal. use a rag and brake clean to clean off and inspect for good seal integrity, these are reusable.
Next use a rag and some brake clean to clean up lower manifold surface, 3m scuffpad can be used to clean any hard spots but care must be taken to insure debris does not enter manifold inlet.
Place a rag over manifold to stop any debris to enter manifold while scraping off old gasket from egr valve.
Once everything is cleaned up, now it is time to install the gasket onto the maniold.
You will notice the lower manifold and spacer have holes for proper gasket placement.
Now You will install the first gasket, ensure correct alignment, place spacer on top, then second gasket on top of spacer aligning all.
you will notice at this point the close contact between egr and gasket.
With a little effort you will have to pull up on egr valve allowing room for manifold to slide under.
Now it is time to install upper manifold, while pulling up egr valve with one hand slide manifold under, after this try to align all gasket and manifold.
Start by placing bolts in holes and shift manifold until able to thread in by hand. do this with all bolts
You can see in the pic the 2 original bolts that were reused. 1 long bolt and 1 stud bolt. lightly snub all bolts, but do do not tighten yet
This will take a little effort to accomplish, the easiest bolt to install first is the EGR stud bolt. pull the egr away from the manifold and slide the bolt through and install gasket. doing this should give you enough wiggle room to allow the bolt to start threading in.
After getting the first bolt in, snug it down enough to get the other in and threaded by hand, snug these bolts down, but do not tighten.
Now go back to the intake manifold bolts and tighten starting from the middle and working your way around in an x pattern or follow the shop manual for specific procedure. tighten all these bolts down till all gaskets are compressed and bolts are tight with the 1/4" ratchet, do not over tighten.
Now tighten down EGR valve bolts.
Reinstall vacuum lines and reconnect connectors
remount DPFE sensor, upper vacuum port line, EGR solenoid, and throttle cable assembly.
Hopefully everything went good at this point and it is all back together, double check for any possible vacuum leaks, and disconnect battery cables to reset pcm memory. :beer:
Link to dyno graph gains tested on my vehicle:
http://i237.photobucket.com/albums/ff277/drewsfbpsi/scan0002.jpg
Tools required:
3/8" ratchet
1/4" ratchet
8mm 1/4" deep socket
10mm 1/4" deep socket
10mm 3/8" deep socket
flathead screwdriver
7mm boxed in wrench
razor blade
3m scuffpad
rags
brake clean
*** recommend new EGR gasket, But not Required***
In these pics my spacer was already installed but will show the process and steps taken to perform modification.
loosen up the 2 8mm worm clamps and disconnect Iat sensor to move intake tube out of the way.
To disconnect the cruise cable, it will unclip upwards, for the throttle cable open throttle body by rotating back and use throttle cable slack to allow cable to fit through slotted portion.
With throttle cable disconnected, unhook the spring connecting the throttle body to cable bracket.
Remove the 2 8mm bolts mounting the bracket to the upper manifold and pull up on the hold bracket for the 2 cables to release it off the 8mm intake stud.
Once unbolted and all cables released place assembly to the side.
Next remove the vacuum line connected to the lower portion off the upper manifold located on the IAC side. Also disconnect the IAC and TPS sensor connectors.
On the driver side of the manifold you will disconnect the rubber hose located next to the EGR solenoid unit, and use the 7mm socket and ratchet to remove the 2 bolts that attach that unit to the manifold.
Use a flatblade screwdriver to pry up on the vacuum line fitting
On the back of the manifold is the DPFE sensor which is held in place by 2 7mm bolts, be careful when removing by hand as to not drop these.
Remove the vacuum line from top of EGR valve to give the rest of the rest of the lines slack. use the 3/8" ratchet and 10mm socket to crack the EGR bolts loose and remove.
Here is the pic with everything removed, all the factory bolts are 8mm blots, loosen and remove all bolts.
Once all bolts are removed, pull up and slide out from under EGR valve
With the upper manifold off use the 3m scuff pad and razor blade to clean up the sealing surface.
At this time use a razor blade and scuffpad to remove any gasket material from EGR mounting port.
Take care when removing old gasket if not purchasing a new one to not cut the seal. use a rag and brake clean to clean off and inspect for good seal integrity, these are reusable.
Next use a rag and some brake clean to clean up lower manifold surface, 3m scuffpad can be used to clean any hard spots but care must be taken to insure debris does not enter manifold inlet.
Place a rag over manifold to stop any debris to enter manifold while scraping off old gasket from egr valve.
Once everything is cleaned up, now it is time to install the gasket onto the maniold.
You will notice the lower manifold and spacer have holes for proper gasket placement.
Now You will install the first gasket, ensure correct alignment, place spacer on top, then second gasket on top of spacer aligning all.
you will notice at this point the close contact between egr and gasket.
With a little effort you will have to pull up on egr valve allowing room for manifold to slide under.
Now it is time to install upper manifold, while pulling up egr valve with one hand slide manifold under, after this try to align all gasket and manifold.
Start by placing bolts in holes and shift manifold until able to thread in by hand. do this with all bolts
You can see in the pic the 2 original bolts that were reused. 1 long bolt and 1 stud bolt. lightly snub all bolts, but do do not tighten yet
This will take a little effort to accomplish, the easiest bolt to install first is the EGR stud bolt. pull the egr away from the manifold and slide the bolt through and install gasket. doing this should give you enough wiggle room to allow the bolt to start threading in.
After getting the first bolt in, snug it down enough to get the other in and threaded by hand, snug these bolts down, but do not tighten.
Now go back to the intake manifold bolts and tighten starting from the middle and working your way around in an x pattern or follow the shop manual for specific procedure. tighten all these bolts down till all gaskets are compressed and bolts are tight with the 1/4" ratchet, do not over tighten.
Now tighten down EGR valve bolts.
Reinstall vacuum lines and reconnect connectors
remount DPFE sensor, upper vacuum port line, EGR solenoid, and throttle cable assembly.
Hopefully everything went good at this point and it is all back together, double check for any possible vacuum leaks, and disconnect battery cables to reset pcm memory. :beer:
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