Can someone help me plan out a CAI?

[JConnX]

My step-dad has agreed to help me make a CAI for my C230 Kompressor this summer. He asked that I get a list of everything I need, though. I've been looking at all the posts on here about it, but no one has seemed to lay it out in simple terms. I'm not an expert on all these motor things that most people talk about, so I'd appreciate it if someone can help me make a list of what I need.

So far I've gathered that I need 3'' piping and an air filter. I've seen people talking about BOVs, though. Do I need one of those? What's the best air filter? K&N?

:) TIA

[jnolte]

BOV as in blow off valve? you dont need one!

I like the Foam filters

[Pagz]

Originally posted by JConnX
but no one has seemed to lay it out in simple terms.
I've seen people talking about BOVs, though. Do I need one of those? What's the best air filter? K&N?

:) TIA

Hi...
Before you venture into the land of intakes,i will help you understand how the 230K system works under various conditions...


The intake system is alittle different from the usual N/A models,theres a SC(Super Charger),VDO Bypass(electronic bypass,which does similar things to a "Blow of Valve")and an IC(Intercooler) before you reach the TB(throttle body).

The SC is ingaged by a magnetic clutch on its drive pully,which is disengaged when at slow speed,low RPM or a combination of both.

Under light load/cruise/deceleration:
The SC is ingaged,the Bypass is open/or partially open and waste charge air(air not being consumed by the engine) is circulated from the SC outlet beside your airbox though the bypass(which is bolted to the airbox),back into the filter box.

Under acceleration:
The bypass closes completely and boost/pressure is created between th SC and TB...as you lift of the accelerator...the bypass opens,which in turn vents pressure into you air filter box and eliminates the build up of pressure caused by the shutting of the TB.

At idle:
the SC is disengaged...And when the SC is disengaged,no air will flow through it,so air is drawn through the bypass valve to feed the engine.

You have a few choices when building the intake,you could custom make it all the way to the SC inlet,or only to where the casting starts...you could position the intake filter in the gaurd,or position it in the OEM location and construct a wall to shield it from engine heat.
One thing remains constant,both bypass and intake need filtration,you can do this by using a similar setup to stock,or you could use two seperate filters.

As far as for the best filter to use...its open to debate...for me i lean towards the dry type(no oil) filter made by Apexi,its a washable filter which has been tested to out filter and outflow similar size K&N filters,to use it you need to make a 4 bolt flange though.
iv just bought two 3" Apexi ones for my bling twin intake yet to be made.
be very careful with foam filters...they usually filter very poorly,which will result in damage to your SC lobes...and of the two foam filters iv used(an HKS and Repco brand) i'll never go back.

three things you may also obtain from the intake:
-a few HP.
-alot of SC whine...so much so it could be alittle intrusive depending on taste.
-a Psssssh noise from the bypass whenever backing off the accelerator after load.

Goodluck with the project!.

Paul

[alphanumeric]

Originally posted by 23K

-alot of SC whine...so much so it could be alittle intrusive depending on taste.




Paul

been there, dont that lol

[JConnX]

So if I position the filter in the guard, then it should be down here, right?

http://i23.photobucket.com/albums/b366/JConnX/ClearCornersintake.jpg

Where would I put the next filter?

I drew this up in paint... This is what I know I need so far. Anything else, or is this about right?

http://i23.photobucket.com/albums/b366/JConnX/caijconnx.jpg

I also noticed that SLAMMED C has a K&N filter for his VDO bypass valve... do I need one of those??

[K_Sport Driver]

well, HE doesn't have it anymore :D

and yes, you do need a small filter there. as he explained, at idle or low speeds when the bypass is collecting the air feeding the motor, it needs to be filtered, lest tiny impurities enter the intake.

[Pagz]

Originally posted by JConnX
So if I position the filter in the guard, then it should be down here, right?

http://i23.photobucket.com/albums/b366/JConnX/ClearCornersintake.jpg

Where would I put the next filter?

I drew this up in paint... This is what I know I need so far. Anything else, or is this about right?

http://i23.photobucket.com/albums/b366/JConnX/caijconnx.jpg

I also noticed that SLAMMED C has a K&N filter for his VDO bypass valve... do I need one of those??

Nice Pic....yeh man install a filter on the VDO bypass...you will need to have a flange made to suit...the rest of the pic looks about right!
copy slammedc's setup and you should be right!...

[Pagz]

Originally posted by K_Sport Driver
well, HE doesn't have it anymore :D

and yes, you do need a small filter there. as he explained, at idle or low speeds when the bypass is collecting the air feeding the motor, it needs to be filtered, lest tiny impurities enter the intake.

have you got that thing on yet man?????;)

[K_Sport Driver]

I was going to ask... can you pm me a DIY on supercharger removal and make my life easy? been working too much to have time for the car :(

[Pagz]

Originally posted by K_Sport Driver
I was going to ask... can you pm me a DIY on supercharger removal and make my life easy? been working too much to have time for the car :(

yeh mang no worries i'll forward you as much as i know...its not a big job,should take about 2 hours to install at a relaxed speed!

[JConnX]

Sweet... I'll start buying the piping and silicone connectors in a couple of weeks. I just bought the K&N filter and AEM Bypass Valve on eBay.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1,1&item=8072718752&sspagename=STRK%3AMEWN%3AIT

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1,1&item=8070747686&sspagename=STRK%3AMEWN%3AIT

Those should fit. What size K&N filter is needed for the VDO bypass valve?

Anyone know the best place to get those red silicone connector deals? :D

and can I get in on that supercharger removal, as well? JIC :p

[K_Sport Driver]

as soon as I get my desktop up and running, i'll post a bookmark I have for an online place with cheap aluminium piping, as I don't have it on the laptop.

and thanks, Paul. I was under the impression that it was going to be a big process, which is why I've been afraid to start! thanks for all your help!