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S197 CAI Install
Tools required: flat and phillips screwdrivers, T20
Torx screwdriver or bit, 10mm socket and ratchet.
Factory air box
removal
Locate the MAF sensor plug on the inlet tube, near the
air box. Unplug it by sliding the red
locking tab back, pressing down on the clip, and then pulling it away from the
tube. A small screwdriver works well to release the retaining clip.
Locate the PCV valve on the passenger side of
the inlet tube, near the throttle body.
Release the locking tab by pushing the green tab back, and pulling away
from the inlet tube. No tools are required for this step.
Follow the same PCV line to the passenger cam (valve) cover
and release the clip from the cam cover.
Pull off the PCV line. The
DeMolet Tunable Induction CAI comes with a new PCV hose, so you will not need
to reuse the factory PCV line.
Next, locate the 10mm bolt at the driver’s side rear
of the air box. Remove it using a 10mm
socket. You will reuse this bolt, so put
it in a safe place.
After the sensors, hoses, and the air box bolt
are all removed, loosen the clamp on the inlet tube at the throttle body. Gently pull it forward, away from the
throttle body. Remove the factory air box.
CAI Installation
The CAI main body for this model comes pre-assembled.
However, you do need to transfer the MAF sensor from the factory tube to the
new CAI tube. The stock sensor uses T20
Torx screws, while the CAI has its own phillips screws. Remove the MAF and install it in the new
inlet tube, making sure you install it in the proper position. There is an arrow indicating direction of
flow. Make sure the open end of the sensor faces the filter. Snug up the screws
for the sensor, but don’t over-torque them.
Install the inlet tube for the CAI onto the throttle body. Lightly tighten the clamp using a socket or
screwdriver. Not too tight, you may need
to adjust it in a few minutes.
Slide the heat shield over the end of the inlet tube, and
then loosely attach the filter. Make
sure the clamp is on the filter before you slide it onto the inlet tube.
After you snug up the filter clamp with a socket or
screwdriver, install that 10mm bolt from the factory air box in the same
location as stock to secure the heat shield.
Leave it loose and check for fitment of the CAI. Make the necessary adjustments for a
satisfactory fit, and tighten up all clamps and bolts.
Reinstall the MAF sensor plug, and secure the red locking
tab by pushing it toward the sensor. It
should click when engaged properly.
Using the new PCV hose from the kit, install one end
on the cam cover. Then, route the hose to the connection on the backside of the
new inlet tube. If you route it on top
of the tube, it may contact the hood insulation. If you route it under the inlet tube, be sure
to properly secure it. The belt and
other moving parts are directly under the inlet tube and you don’t want the PCV
hose to come in contact with any moving parts. I recommend using a zip tie and
securing the hose to the TOP of the metal bracket directly under the throttle
body. Double check to make sure the hose
will not contact the belt.
This CAI needs a tune to operate properly, so re-flash your
computer according to the manual for your tuning device. This CAI comes with an SCT XCAL2 tuner. Once the tune is installed, start the engine
and review your work. Check for leaks,
and double check for fitment. If
everything is fine, you are now finished.
DO NOT run this CAI without a tune. Without a professional tune, your engine will
run lean due to the larger inlet tube.
If you run the engine without the tune, you can damage your engine.
With the addition of the intake and tune the throttle
response is much improved, throttle lag is gone, and power has increased
noticeably. You may think you are
driving a completely different car, the difference is that big!
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