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

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).

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.

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

finally, intall pics

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

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

fun threading the OEM screws into here... i wonder.. was my kit missing new hardware for this location?

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!

this whole thing was way harder than it should have been.. haha.. but man does it sound good! Stay tuned for gas mileage reports.

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)

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

1:9 twist

Our Vendors

Top Contributors this Month

Recommended Communities