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Gen2 - Volant Cold Air Intake CAI - horn relocation - DIY 'ram air'

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7K views 41 replies 7 participants last post by  asugm13  
#1 · (Edited)
A bunch of us were able to pick up somewhat of a great deal on the Volant CAI. Here are my tips/tricks, install pics and more. For more background check out this thread: http://www.clubxterra.org/forums/showthread.php?t=8857

my install quick tips...
  • check your kit, mine was missing: the horn relocation bracket, a 1/4" lock washer, MAF gasket, idk if they are suppose to come with the kit but I think it should have come with MAF screws, the stock did not work for me, I also think we should receive the ram air scoop like the frontier's, same kit, same cost, we could fashion it to work I believe. Some of you may not need the horn-relo kit, idk what years/models but some are mounted in front of the radiator, mine were below the stock air box.
  • unhook your battery to 'reset' your computer - be ready to whine when you have to reset your radio settings
  • for some of us 2nd gen guys our horns will be in the way, take'm out of the way
  • remove the air box, and the rest of the pieces up to the throttle body, stuff a clean rag into the end to keep any dirt from getting inside, the engine cover with the 4.0 on it needs to come off or at least partially. There are two screws and then snap fittings, at least pop the front up/off to get at the bolts holding on the OEM intake tube.
  • see the pictures below for what wiring harness spots that need to be moved, possibly a ground may need to be removed
  • now that everything is out.. test fit all the bolts/screws you'll be using into their respective locations... AKA three spots for the air box, and two spots on the new intake tube where the sensor goes in.. the new hardware doesn't fit very well, especially the sensor fittings and the top screw for the air box and the test fitting of the bolts will get you familiar with the angles they need to go in, and will also loosen up the fittings.. some of mine were tight..
  • I basically had to thread the sensor fittings.. Almost stripping the screw heads in the process.. I ended up using a small pair of vice grips to grab the head and torque them in.. I had to do this once the tube was already installed... Do it before installing.. They don't have to go all the way in.. the sensor keeps them from having to go all the way down to be tight.. when you get to it you'll see what I mean..
  • My air box was a PITA for me to bolt in.. It was like they scaned the engine bay with a laser mapping system (and that system was off by a quarter to half an inch).. lol.. Start with the lower bolt and do not tighten it down very much at all, just enough to get a good hold, then to the next one up, again just enough for a good hold, then do the top.. Some guys have just made the holes bigger, might be a better idea, that way your box isnt torqued, might make the top lid fit bad
  • I suggest installing the mass air flow sensor MAS into the new intake tube before you install the tube under the hood. Pay close attention to the fitting of the OEM gasket and the new tube. Mine was very poor and required me to use some gasket maker (see pictures) BUT your kit is suppose to come with a gasket if it inst there
  • the rest is pretty self explanatory

3 different packages came from volant and I am still missing a 1/4" lock washer (requested two different times, and requested screws that would work with THEIR MAF location never received either - stock screws didnt work for me.) I also think we should receive the Ram air scoop, it was on my parts/packaging list, I believe its more meant for the frontier but could be a part we could fashion other places.

1st shipment I received from Volant (credit dezurtrat for the filter below, i was lazy and didn't get a pic of it).
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2nd shipment from volant (requested 1/4" lock washer that did not come with kit, did not receive it)
Here is the relocation bracket volant should provide you if your horns are in the way. However, just like the CAI there are no directions/tips on how you might want to use it. I ended up just using the hardware that came with the bracket.
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3rd shipment, found out kit was missing the gasket for the MAF, (requested correct MAF screws and 1/4" lock washer again, did not receive either) and I think they use the heaviest envelop created, it actually has insulation in it.. lol
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finally, intall pics
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seriously.. is this really a ground?.. Im thinking about beefing this cable up.. And the jury is out on if the wire connection is in the way for the airbox.. I need to check mine.. maybe thats another reason it was so tight
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You may need to move this wiring harness like I did, snip the connection here and just keep out of the way when installing the air box
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fun threading the OEM screws into here... i wonder.. was my kit missing new hardware for this location?
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After a week of driving my engine light came on because the seal around the MAS was leaking.. IMO ditch the OEM gasket and use some gasket maker.. No more engine light for me - EDIT your kit should come with a gasket!
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this whole thing was way harder than it should have been.. haha.. but man does it sound good! Stay tuned for gas mileage reports.
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Follow-Up
Installed Volant w OEM gasket - 3/18/2009
Check engine light (SES) came on - 3/24/2009
Did RTV gasket (SES light went off) - 3/26/2009
SES back on - 4/8/2009
Leaving work SES is off on start up - 4/13/2009
SES back on - 4/24/2009 (must have heard I ordered a superchips the night before)
 
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#8 ·
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#9 ·
While I plan out the ram air mod... I decided to do the plug LA RANA showed us and others have done so here are the pics. If you have trouble finding it just print these pictures and you'll be all set. I went looking for an actual rubber stopper but this is an end cap for 2" pvc, lucky for us the outside measurement is just over 2.5" so its a perfect fit for the open hole in the volant CAI.

If your looking to get this for yours.. go ahead and print me! and take me to home depot/lowes or wherever sells piping
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#10 ·
this post is dedicated to SHADOW

I was never to much of a fan of the 'carbon fiber' lid.. so I took some spray paint to it this weekend.. if I was to do it again I might use a satin/semi-gloss instead of flat.. But I think it came out good.

A side note for those who do like the lid and the colors.. I suggest giving it a couple clear coats or other protective coating.. because I was going to paint it black i gave the dark blue above the 'volant' a little scratch with my thumb nail and it came right off no problem. You'll see in my pic below I ended up scrubbing the rest of the color off.. which may be another good idea.. just buff off the colors and you'll have more of a chrome look..

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#13 ·
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#14 · (Edited)
here is a sweet functional ram air hood for the titan.. they need to make a hood for the xterra.. I may email them.. haha.. not that it would work really with the volant.
http://www.suncoastramairhoods.com/eshop/shop/index.php?productID=366
http://www.clubtitan.org/forums/showthread.php?t=53644
another
http://www.octanemotorsports.com/product_info.php?products_id=3414


here are some other inlets/hoses sites got a few items.. these items are normally used for brake cooling/seat cooling..
http://www.pegasusautoracing.com/advcat.asp?CategoryID=BRAKEDUCT
 
#15 ·
#16 ·
#18 ·
I received the horn relocation bracket from volant finally (see pic at beginning of thread). I had also asked they send me a quarter inch lock washer that was missing from the CAI kit. But they didn't send it.. So much for customer satisfaction. The CAI kit came with an assembly chart, but did not really include what I would call installation instructions. This would remain true with the relocation bracket I received. Your forced to used your imagination. And I used mine.

I did not want to put the horns near the intake box again because of the eventual addition of a DIY ram air mod. I remembered other members talking about and also seeing posts of the horns located just in front of the radiator so I removed the grill and shown below are two spots I found acceptable for relocation.
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#19 ·
I loved the second spot shown above. It tucks the horns inside of part of the front valence/bumper. The nut/bolt/washer combo that came with the horn relocation was PERFECT for this spot as well!

I tapped and drilled a hole in the valence bracket to line up with the existing hole in the OEM horn bracket. If you wanted to make it a little cleaner I suppose you could drill another hole in the OEM bracket so everything was centered. I shot the exposed metal after drilling with some spray paint to protect it.
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#21 ·
thats all the time I had this weekend, wiring to come. for those gen2's out there that have their horns mounted in front of the radiator: could you tell me or supply a picture of where your horns wiring hooks up to? Im trying to figure out if I have a nicer option than just splicing and running wires up to where they used to plug in near the air box.
 
#22 ·
Use some of the split corrugated loom that is used on allot of automotive wiring harnesses. The plastic stuff. You can buy it at most auto parts stores. Nice work BTW!
 
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