My K&N RX-4750 arrived today, completing my parts list for my intake upgrade. I was using a drop-in K&N filter in the stock airbox before. My install is virtually exactly the same as Tumbleweed'* 96 SSE, but I don't have a loose PCM and my air intake temp sensor is different. But I used exactly the same parts, literally cutting and pasting from his post:

Auto Zone pipe part # 8219 $42.00 (cut down by 4")

K&N RX-4750 from AJ USA $49.00
http://www.ajusa.com/cgi-bin/knfilte...27e2373051b38a

Silicone 4" - 3" reducer part number PWRR40-300/400 $26.00
http://www.pwr-performance.com/coupler.htm

$117.00 for parts and about 2 hours to install.
I used a hot soldering iron to slightly enlarge the air intake temp sensor hole in the K&N filter, based on other people saying that worked well. It did.

Before starting project:


Stock airbox removed (and old sticker):


The Autozone rice pipe:


I used a hacksaw to cut off about 4" off the pipe. Deburred with emery paper and a file. 4" to 3" silicone reducer is attached:


The cut-down intake with the air filter, air intake temp sensor, and the lengthened wiring for the temp sensor:


The lengthened temp sensor wiring installed and split-loomed into the wiring harness:


Temp sensor plugged into the K&N filter:


I made a shield out of this aluminized insulation I had lying about. I don't know what this stuff is called. It'* very simple, and I think it does the job:


The completed intake installed. Engine cover is off:


All finished and buttoned up:


Test drove: WOW! This makes a definite improvement! When I had the dual exhaust Magnaflow muffler installed, I'm certain that I lost some low end torque. In fact, it was mildly annoying. Now it'* all back and then some! And there'* a growling beast lurking under the hood of my car. Now it has a strong, powerful pull all the way through the RPM ranges, and it literally feels like it leaps and awakens to life when I step on what I now call "the happy pedal"!

Seriously folks, this is, in my opinion, the biggest bang-for-your-buck DIY modification you can make, followed by ordering a performance muffler and some tips and paying an exhaust shop to weld them on. Together, they make a mighty improvement. There is a "snorkeling" noise on cold startup that others have mentioned, but it went away after about 60 seconds.

I'm very impressed with this upgrade, it makes quite a difference!

Nice. Wrap that foil all the way around the filter now to make it a CAI

Looks good but,You definately need to close it off or you will keep getting hot air from the engine compartment. I have mine closed off and I also used a 4"-3" rubber reducer and some 3" hose to make a "home depot ram air" coming from under the bumper and am within 5* of ambient

This is how I did mine,It'* got a cover of the same insulation I used to make the box over it now.



Also,take the cover off of the engine it will help keep it cooler

Bugsi,

Does the side of your filter rub against the PCM cover? I was tempted to mount mine similar to yours but I didn't want any continuous side pressure on the silicone coupler. I see you were able to fit the filter into the corner in a verticle fashion and I have mine running horizontal after laying the PCM on it'* side.

Just wondering how you were able to make it work.

Looks nice!

Tumbleweed

Tumbleweed, take a look at this photo I took after just removing the stock airbox:


Question: Is the big black plastic box to the right of the stock airbox location the PCM? Guessing that it is, did you take yours out of the plastic box before mounting it sideways under your air filter? That'* what I'm guessing.

I just sort of shoved my K&N into that space vertically. It doesn't rub against the black plastic thing (guessing that'* the PCM cover) but the rice pipe kind of goes into the silicone reducer at a bit of an angle, rather than perfectly straight. I think I'm okay with it, it clamped down fine.


-Mark (Bugsi)

Nice work.. it looks good so far. I'd also suggest a solid/enclosed heat shield however as others have.

Bugsi: yes that "black plastic thing" is the cover to the PCM

Ah, okay. Good to know. Y'know, when I was younger I pulled the engine from my 78 Bonnie, had it rebuilt, then dropped it back in and drove it away. I knew what every part was on that Buick 350 V8. But man, I look at the engine in my 97SE and just shake my head. I dunno what I'd do without you guys. Here I sound like an old fart at 38.

Bugsy, you haven't needed to do much under there yet. It'* still nearly as simple. Except you can't put the distributor in backwards, there'* no carb to mess.

A lifter is still a lifter and pistons still make them work.

Good write-up with excellent pictures!! With some tweaking, it would be a good TechInfo article IMO.