Thanks to Steve Cockrill of CS TEXAS for this awesome How To!
1. Materials:
1.1: Socket wrench and metric socket set with extension bar(s).
1.2: Philips head screwdriver(s).
1.3: Electric drill and bit set.
1.4: Clean, damp cloth.
2. Step One:
-Open hood and remove front bumper-
2.1: Open the hood, and remove the negative battery terminal from
the battery, but if you have a stock stereo, remember to note the
radio code!! Over the top edge of the bumper (covered by the
hood) you will see several black, flat Philips type screws with rubber
gaskets. Remove those. There will be a black metal retainer
that comes off after all are removed.
2.2: Then, get under the car. There will be 10 mm bolts (2) that need to be removed with the socket wrench.
2.3: Here is the interesting part. There are hidden Philips head screws (2) connecting the sides of the bumper to the front quarter panels (one on each side). Remove the front part of the plastic wheel arch cover (3 screws). Reach inside the quarter panel to where the screw is, and using a small Philips head screwdriver, remove the screw. Be careful at this point and ensure that the bumper is supported so it does not hit the ground and get damaged.
2.4: Step One complete. Estimated time: 20 min.
3. Step Two:
-Removal of stock intake system-
3.1: The stock intake is basically composed of four parts. The
first is the intake head, which is from where the system draws air.
The second is the resonator box, then the filter housing, and finally
the intake duct.
3.2: Here the locations of the stock intake components are shown in the car.
3.3: The first step is to pull out the intake head. The filter housing and intake duct are then ready for removal. The intake duct is attached to the throttle body by a single clamp. Loosen the clap with a small Philips head screw driver. The filter housing is held in place with three 10 mm bolts, located as shown in the photo -
3.4: After removing the bolts, the filter housing and intake duct are removed from the car.
3.5: The final step in removing the stock system is to remove the resonator box from the wheelwell area. There are three 10 mm bolts that hold the box in place, and which may not be obvious at first. One is located under the car. Due to the shape of the box, it is also difficult to remove from the wheelwell. Pull down on the driver's side of the box first, as shown in the photo -
3.: Step Two complete. Estimated time: 25 min.
4. Step Three:
-Installation of Iceman Cool Air System-
4.1: The Iceman system requires a little preparation before installation
in the car. First, a 0.5" hole is drilled in the blank
protrusion on the upper intake duct. The brass fitting is then
carefully screwed in place, by hand as far as possible to make sure
that it enters straight. A 13 mm wrench is used to tighten it,
but avoid overtightening. The purpose of the brass fitting is
to allow the valve cover breather hose to route into the intake cleanly.
4.2: The smaller blue connector sleeve is then placed on the small
end of the upper intake duct, and clamped securely using a hose clamp.
The mounting hardware assembly is attached to the threaded bushing
on the underside of the upper duct, but not tightened to allow adjustment.
4.3: Attach the upper intake duct to the throttle body using the connector
sleeve. Secure, but do not overtighten the second hose clamp.
Attach the other end of the mounting hardware to the car body, using
the closest existing bolt hole from the stock filter housing.
4.4: Install the black trim piece around the resonator box inlet hole.
This prevents scraping of the lower intake duct during installation,
and makes for better looks.
4.5: Slide the larger blue connecting sleeve onto the end of the upper
intake duct. Securely clamp the sleeve to the upper duct.
From inside the bumper area, pass the smaller end of the lower duct
through the resonator box inlet hole in the bodywork. Attach
the lower duct to the upper duct, and tighten the clamp.
4.6: Attach the K&N cone filter to the end of the lower duct, and firmly secure with the clamp.
4.7: Make sure all the components are aligned properly,
and tighten the remaining clamps and mounting hardware bolts.
4.8: Re-connect the negative battery terminal. Turn power on to the
car, and crank it up!!! Ta-dah!!! The intake should make
a distinct sucking sound at idle.
4.9: Step Three complete. Estimated time: 25 min.
5: Step Four:
-Install breather and coolant hoses-
5.1: Attach the breather hose to the brass bushing, and clamp in place.
Use additional lengths of hose to replace the coolant hose, since
the stock metal tubing and lines will not be reinstalled.
5.2: Step Four complete. Estimated time: 5 min.
6: Step Five
-Re-assemble bumper-
6.1: Re-assemble the bumper, in the reverse order that it was disassembled.
6.2: Attach the included decal, if desired.
6.3: Enjoy your new intake system!!! The Iceman should provide
approximately 10 to 15 hp at the flywheel on a stock Si engine.
6.4: Step Five complete. Estimated time: 10 min.
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