Ok Here you go its is the proper way to do a cai this works perfectly with the 2.2 lter ecotec engine yet is identical to the other engines of the late model cavs. if anyone can do better please speakup. Well anyway here is how you do the install. Step 1 make sure the car is parked on a level surface p brake set disconnect battery and remove, if engine has run in the past 2 hours let it cool down. jack up the car and remove the driver side front wheel.
step 2-- remove the stock intake by pinch spring clamp and pull the breather hose off of the valve cover, pull the vacum hose off of the inlet pipe, if equipped. pull the IAT sensor out of the pipe. remove the rubber grommet and save for later. relase the hose clamp located at the throttle body with a flat head screw driver. relase the hose clamp at the upper air box flat head. remove the throttle body airbox and inlet hose from the engine bay. loosen the battery hold down bolt and remove the battery. Release the two wire ties on the air box. remove the fuse box fastener. remove the upper air box from the vehicle.now move over to the wheel well and remove the screws and plastic retainers that secure the fender liner(6 total).under the car remove the screws and plastic retainers that secure the fender lliner 4 total. release the wire tires, unplug the washer motor and pull the hose from the washer motor. catch the washer fluid in a container. remove the two screws inside the fender well that secure the washer bottle to the vehicle. Remover the screw near the front of the vehicle that secures the washer bottle to the vehicle. remove the screw that secures the washer bottle to the vehicle above where the last one was removed from. Release the snorkel from the vehicle by pulling it towards the outer fender. Remove the botttle from the vehicle. release the bolt that secures the bottle to the lower air box and seperate.
Step 3-- Installation of the CAI. apply a rubber pad 4x6" in the area where the old box sat. install the rubber mount from inside the engine bay to the right side innner fender behind the battery tray there is a hole already.secure the other end with the washer and bolt. install the supplied bolt and washer through hole in strut tower secure the other side with a washer and lock nut. Place the inlet pipe in the engine bay sure u can figure out hopw it goes place bolts in place just not tighten them yet. affix the 2"x4" rubber material to protect the pipe from rubbing on the sharp metal around the hole. if need remove pipe and place the rubber first and reinstall the pipe. install a rubber mount to the fuse box tab mount. Place the bracket under the the washer that was bolted at the strut tower. secure the fuse block to the rubber mount with a lock nut and washer. confirm that all wires are router corrctly to let the box @!#$ like oem. you may have to lossen the pos feed the box to move so it does not contact the air pipe. install the hump hose onto the end of the pipe. do not tighten the hose clamp. Install the short silicone hose onto the throttle body. Install the stock grommet into the hole on the intake pipe place the end of the pipe over the throttle body. Mate the two pipes together using the supplies hump hose. make sure when you clamp the the extra clamp feeds off away from the battery. Install the IAT sensor in the intake pipe. Install the supplied breather hose to the valve cover and pipe near the throttle body. Place the air filter onto the other end of the pipe. tightenall bolt you left loose including clamps replace the battery and washer bottle with out the lower air box. if your stock throttle body air box had a nipple next to the sensor remove the hose up to the fuel pressure regulator this is a vacum hose just replce with a little filter like 3-4 bucks at pep boys. replace the wheel well and wheel and test drive. after about 100 miles or so check the connecter where the pipes join with clamps they may come loose . any question hit me up other then that enjoy i also have pic of mine install and what really comes out of the car (oem crap). later -Wayne
wayne f wrote:Ok Here you go its is the proper way to do a cai this works perfectly with the 2.2 lter ecotec engine yet is identical to the other engines of the late model cavs. if anyone can do better please speakup. Well anyway here is how you do the install. Step 1 make sure the car is parked on a level surface p brake set disconnect battery and remove, if engine has run in the past 2 hours let it cool down. jack up the car and remove the driver side front wheel.
step 2-- remove the stock intake by pinch spring clamp and pull the breather hose off of the valve cover, pull the vacum hose off of the inlet pipe, if equipped. pull the IAT sensor out of the pipe. remove the rubber grommet and save for later. relase the hose clamp located at the throttle body with a flat head screw driver. relase the hose clamp at the upper air box flat head. remove the throttle body airbox and inlet hose from the engine bay. loosen the battery hold down bolt and remove the battery. Release the two wire ties on the air box. remove the fuse box fastener. remove the upper air box from the vehicle.now move over to the wheel well and remove the screws and plastic retainers that secure the fender liner(6 total).under the car remove the screws and plastic retainers that secure the fender lliner 4 total. release the wire tires, unplug the washer motor and pull the hose from the washer motor. catch the washer fluid in a container. remove the two screws inside the fender well that secure the washer bottle to the vehicle. Remover the screw near the front of the vehicle that secures the washer bottle to the vehicle. remove the screw that secures the washer bottle to the vehicle above where the last one was removed from. Release the snorkel from the vehicle by pulling it towards the outer fender. Remove the botttle from the vehicle. release the bolt that secures the bottle to the lower air box and seperate.
Step 3-- Installation of the CAI. apply a rubber pad 4x6" in the area where the old box sat. install the rubber mount from inside the engine bay to the right side innner fender behind the battery tray there is a hole already.secure the other end with the washer and bolt. install the supplied bolt and washer through hole in strut tower secure the other side with a washer and lock nut. Place the inlet pipe in the engine bay sure u can figure out hopw it goes place bolts in place just not tighten them yet. affix the 2"x4" rubber material to protect the pipe from rubbing on the sharp metal around the hole. if need remove pipe and place the rubber first and reinstall the pipe. install a rubber mount to the fuse box tab mount. Place the bracket under the the washer that was bolted at the strut tower. secure the fuse block to the rubber mount with a lock nut and washer. confirm that all wires are router corrctly to let the box @!#$ like oem. you may have to lossen the pos feed the box to move so it does not contact the air pipe. install the hump hose onto the end of the pipe. do not tighten the hose clamp. Install the short silicone hose onto the throttle body. Install the stock grommet into the hole on the intake pipe place the end of the pipe over the throttle body. Mate the two pipes together using the supplies hump hose. make sure when you clamp the the extra clamp feeds off away from the battery. Install the IAT sensor in the intake pipe. Install the supplied breather hose to the valve cover and pipe near the throttle body. Place the air filter onto the other end of the pipe. tightenall bolt you left loose including clamps replace the battery and washer bottle with out the lower air box. if your stock throttle body air box had a nipple next to the sensor remove the hose up to the fuel pressure regulator this is a vacum hose just replce with a little filter like 3-4 bucks at pep boys. replace the wheel well and wheel and test drive. after about 100 miles or so check the connecter where the pipes join with clamps they may come loose . any question hit me up other then that enjoy i also have pic of mine install and what really comes out of the car (oem crap). later -Wayne
Does this apply to the 2.4 cavalier 2001 as well??
WOW thats all im going 2 say
13.1 @ 115
nice to see ya took some time to make a write up ..
Now who will make a write up on how to install stickers?
Matt wrote:Now who will make a write up on how to install stickers?
he took some time to be helpful hence it is in the noob section..
if more ppl were helpful like him we wouldent have to look at 15 diffrent posts to find one answer
