Well, looking for some cheap mods to do until I do the FI, I decided to buy a cheap intake and give it a go. There it is, 2.4L polished WAI I bought for $35!!
I removed the ugly stock expansion airbox, and there was hard vacuum lines attached to the box, I replaced that with some blue silicone hose I had...I had nowhere to attach it to, so I discovered two capped connectors on the intake manifold, I pulled off one of the rubber caps and connected the vacuum hose there.
Next I removed the stock airbox..it was easy as hell, not ONE bolt like my old one...basically I loosened the connecter that locks the battery in place, removed it... removed the fuse cover and pulled out the clip by the washer fluid cap...I lifted up fuse box and popped off the intake box where it connects to top of BONG, and pulled the box forward to pop it out of the holder by the firewall..viola, it was out just like that.
That metal bracket attached to the tube (see pic#1) got in the way...I had to bend it straight down, then hammer the "L" straight...it will need to be held down by a bracket, right now it's just got zap straps holding it in place..lol..
For the valve hose, I didn't have any silicone tube, so I grabbed some rubber fuel system hose from my MSD fuel pump, and routed that from valvecover to connector on the intake. For the IAT air sensor, i removed the grommet that came with it as it was too narrow, and removed the grommet that houses the intake sensor on the stock air expansion box and used that one.... the new location was over behind the battery and it the grommet and sensor fit like a glove!!
I put some chalk dust on the silicone 90deg coupler and closed hood.. I opened up hood and there was NO chalk on the hood liner... so clearance looks good. I took the car for a test drive and wow.... a lot more midrange power...I didn't hear any intake sounds, but the stock exhaust sounds MEAN, it seriously sounds like I have an aftermarket exhaust system when I punch it!!!! After driving around for 35 minutes on the highway and around the streets, I opened hood and there was no rubbing or any evidence of contact with the rubber TB connector and hood liner, however I will keep an eye on this and advise if I see any rubbing.
Power difference is noticable, I feel extremely happy with a $35US purchase and I am sure this performs just as well as any of the $150 - $200US WAI intakes. You can find this intake on ebay in many forms, I got mine from Cosmo racing, there's also the bomz racing one and a few others...the pipe is more or less the same, but they are all
slightly different...the cosmo fit the best. NOTE: '02 cavaliers have a bit less clearance
for some reason and this intake may not fit without rubbing on hood... not a problem if you have motor mounts...this intake fits on '03+ sunfires with room to spare, '03 cavaliers have less clearance due to hood design, but with some adjusting, it will fit!
- FF22
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RIP FF22: 1996 - 2003 (1996 Pontiac sunfire 2.2 OHV, showcar) <br>
<img src="http://images.cardomain.com/member_images/4/web/436000-436999/436638_13_full.jpg">
So your telling me that a 2.4 intake will work...
Which seller did you order from, possibly post a link?
I wish I han't cut up my old Bomz WAI..... whoops
12.770 @ 111.99 Intercooled Eaton M62
Check my post, it's in there....I got mine for Cosmo racing in canada, off ebay. <br>
RIP FF22: 1996 - 2003 (1996 Pontiac sunfire 2.2 OHV, showcar) <br>
<img src="http://images.cardomain.com/member_images/4/web/436000-436999/436638_13_full.jpg">
