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-   -   DIY: Vararam CAI Install with Color Photos (http://www.camaro5.com/forums/showthread.php?t=59740)

Jeanius 01-07-2010 06:31 PM

DIY: Vararam CAI Install with Color Photos
 
Work in Progress. Still need to finish the last few steps PLEASE DO NOT POST UNTIL I FINISH!!

FIRST OFF!

Make sure you have everything that is supposed to be included in your kit. That way you dont start pulling off the stock assembly only to find you cannot install and run your Vararam because your missing something.


Step 1: Gather your tools

Here is what is recommended from Vararam

Flathead Screw Driver
10mm Deep Well Socket
Pliers
T15 Torx

Also get yourself

Philips Screw Driver
Tape Measure
Wire Cutters
Scissors

http://i254.photobucket.com/albums/h...Y/DSC06724.jpg


Next, Remove the 2 lock nuts shown, and loosen both the band clamps at the Throttle Body and air box so you can remove it. All you need to do is break the lock nuts loose, then use your hands to unscrew them all the way.

http://i254.photobucket.com/albums/h...Y/DSC06723.jpg
http://i254.photobucket.com/albums/h...Y/DSC06729.jpg
http://i254.photobucket.com/albums/h...Y/DSC06730.jpg



Next, unplug the MAF Sensor and then disconnect the tubing from the stock air box.

http://i254.photobucket.com/albums/h...Y/DSC06727.jpg
http://i254.photobucket.com/albums/h...Y/DSC06732.jpg


Now, pull on the stock air box to release it from the grommet holding it on the bottom. Mine required ALOT of oomph.

http://i254.photobucket.com/albums/h...Y/DSC06734.jpg
http://i254.photobucket.com/albums/h...Y/DSC06735.jpg

Now, you can either disconnet the PCV hose that runs from the intake to the intake manifold at the manifold or the intake. I removed it from the intake manifold.

You have to twist the entire tubing to expose the side of the connector that has a little clip. Push the clip with your Flathead and pull on it to release. After removing it I found that you can also just pull and it will come out of the stock intake tubing.

http://i254.photobucket.com/albums/h...Y/DSC06737.jpg
http://i254.photobucket.com/albums/h...Y/DSC06738.jpg
http://i254.photobucket.com/albums/h...Y/DSC06739.jpg


Now remove the 2 clips that hold hold the radiator in place using your 10 MM socket.

http://i254.photobucket.com/albums/h...Y/DSC06741.jpg
http://i254.photobucket.com/albums/h...Y/DSC06740.jpg


Now remove the rubber/plastic liner that is on top of the condenser. there are 4 little grooves that hold it, use your Flathead to unclip it from each one then just pull it off.

http://i254.photobucket.com/albums/h...Y/DSC06742.jpg
http://i254.photobucket.com/albums/h...Y/DSC06743.jpg
http://i254.photobucket.com/albums/h...Y/DSC06744.jpg


Now remove the MAF sensor from the stock assembly using the T15 Torx.

http://i254.photobucket.com/albums/h...Y/DSC06745.jpg
http://i254.photobucket.com/albums/h...Y/DSC06746.jpg
http://i254.photobucket.com/albums/h...Y/DSC06747.jpg
http://i254.photobucket.com/albums/h...Y/DSC06748.jpg


MAKE SURE that your rectangular O Ring came out with your MAF, if it didnt, MAKE SURE you get it off of the stock assembly. You will use this on the Vararam Unit.


The MAF can only be mounted into the Vararam one way, so you dont have to worry about putting it in wrong.

Slide it into the Varam Unit and ensure the holes line up.

http://i254.photobucket.com/albums/h...Y/DSC06749.jpg
http://i254.photobucket.com/albums/h...Y/DSC06750.jpg
http://i254.photobucket.com/albums/h...Y/DSC06751.jpg


Use the Screws and Nuts provided to secure it with a Philips Screw Driver. The washer goes onto the screw before you put it on the MAF. There will be a space between the metal piece and the Vararam MAF housing. THIS IS NORMAL. DO NOT OVER-TIGHTEN TO THE POINT IT BENDS!

http://i254.photobucket.com/albums/h...Y/DSC06752.jpg
http://i254.photobucket.com/albums/h...Y/DSC06753.jpg
http://i254.photobucket.com/albums/h...Y/DSC06754.jpg
http://i254.photobucket.com/albums/h...Y/DSC06756.jpg


Now take the gasket flap and trim 1 piece to 8" and the other to 4". Use scissors on the part without the metal and wire cutters on the metal part.

http://i254.photobucket.com/albums/h...Y/DSC06758.jpg

Now this is the part that took me the longest. I dont think my radiator tilts back as much as their did so I didnt have as much room. Getting these 2 pieces to stay on the Radiator Shrouding took me forever

Clip the 8" onto the passenger side shrouding along the rim with the foam. Mine required A LOT of force to get it to go in deep and stay. Also clip the 4" piece onto the drivers side. Here is what mine looked like. I was able to get them a little further after these pictures.

http://i254.photobucket.com/albums/h...Y/DSC06764.jpg
http://i254.photobucket.com/albums/h...Y/DSC06760.jpg

Now install the Vararam rubber Radiator Grommets. Instructions say to use the 4th louver but mine had one of those clip things that was holding the rubber/plastic lining that was on top of the condesor, so I used the 5th.

http://i254.photobucket.com/albums/h...Y/DSC06834.jpg

Now install the RED hose onto the TB and slip the 2 band clamp over it. You can tighten them up a little so they wont be so lose and fall off, but it doesnt really matter. Make sure you put them on in a way you can get to the screw to tighten them.

http://i254.photobucket.com/albums/h...Y/DSC06835.jpg

Now your ready to drop the the Vararam Unit.

Put it into the car with the air inlet side first, get it to rest atop the A/C condensor and then guide it back until the bottom of the Throttle Body opening rest on the bottom of the red hose.

http://i254.photobucket.com/albums/h...Y/DSC06766.jpg
http://i254.photobucket.com/albums/h...Y/DSC06841.jpg
http://i254.photobucket.com/albums/h...Y/DSC06848.jpg
http://i254.photobucket.com/albums/h...Y/DSC06850.jpg


Wedge a Flathead between the Vararam TB Opening and the RED hose and push the opening into the hose, now run the flat head along the hose to pop it all out and get it to cover the Vararam TB opening. Then tighten the band clamps. One around the rim of the Vararam and the other on the rim of the TB.

http://i254.photobucket.com/albums/h...Y/DSC06768.jpg
http://i254.photobucket.com/albums/h...Y/DSC06842.jpg


Now plug in your MAF sensor. Route it as the pictures in your Vararam instructions show, I will post up a pic soon.

http://i254.photobucket.com/albums/h...Y/DSC06858.jpg


Now Measure out your PCV Line by attatching it to the Intake Manifold first, and running it to the Vararam whatever way you like. You might want to give yourself a little slack JIC, then cut it to size using the wire cutters.

http://i254.photobucket.com/albums/h...Y/DSC06852.jpg
http://i254.photobucket.com/albums/h...Y/DSC06854.jpg
http://i254.photobucket.com/albums/h...Y/DSC06856.jpg
http://i254.photobucket.com/albums/h...Y/DSC06857.jpg


Now make sure you got all your tools, extra gasket/hose pieces out of the engine bay. Again MAKE SURE everything is accounted for. MAKE SURE the inlet of the Vararam is close to the top of the A/C condensor, and look under it to see if its resting upon the Vararam Condensor Grommets.

http://i254.photobucket.com/albums/h...Y/DSC06866.jpg



NOW Fire Her UP! Let it learn the new Idle for 10 Min. DO NOT REV IT!

Run it normal Stoplight to Stoplight, some Freeway driving for 30-40 miles before you do any spirited driving.

Vararam suggest logging a total of 100 miles of mixed city/freeway driving before WOT pulls or Dyno'ing the car.

If you have any issues, such as erratic idle, CEL etc... Call Patrick at Vararam. He will take care of you.

And there you have it. I think I included everything. If I forgot something please PM me. Like I said before the Vararam Instruction are pretty detailed. I just did this for anyone who wanted COLOR photos.

LS3SSRS 01-08-2010 12:47 AM

nice writeup dude! cant wait to get mine.

2SSRS@Gen5diy 01-08-2010 10:04 AM

Nice job.

Sherwood SS 01-16-2010 11:39 PM

Great write up. Need some finished pics now.

Jeanius 01-17-2010 01:07 AM

Still waiting on the replacement unit to get here guys. The stocker is on right now.

monstertodd 01-17-2010 02:38 AM

Would it be possible to get this DIY in black and white photo's?


:D

Jeanius 02-03-2010 09:04 PM

Quote:

Originally Posted by monstertodd (Post 1388475)
Would it be possible to get this DIY in black and white photo's?


:D


Sure, when you print it do it in Blk/White! :thumbsup:

DIY is now complete.

cdn2usa 02-06-2010 07:19 AM

Great write-up.

Was that the tune or no-tune model you installed ?

I am on their wait list for the second production run (no-tune model)do out in March.

Jeanius 02-08-2010 09:23 PM

Quote:

Originally Posted by cdn2usa (Post 1454590)
Great write-up.

Was that the tune or no-tune model you installed ?

I am on their wait list for the second production run (no-tune model)do out in March.

No tune

TAG UR IT 02-09-2010 01:56 AM

This is the final version, correct? And, how is it running? What size filter?

FwyFlyer 02-09-2010 01:00 PM

size matters
 
Quote:

Originally Posted by TAG UR IT (Post 1464391)
This is the final version, correct? And, how is it running? What size filter?

How or where are we to measure to determine the size of our unit? :facepalm: (did I really say that!)

TAG UR IT 02-10-2010 12:36 AM

lol! Measure from the base to the tip...:laugh: Dude...that's horrible...

base to top. ONLY filter size. Pretty sure that if you get an auto, it's 2.5 for you. If you get m6, it's 2.75

NEIL F1 03-23-2010 10:53 PM

VARARAM ISSUES?
 
IS THER A BIG DIFFERENCE AND ANY ISSUES WHAT SO EVER CHECK ENGINE LIGHT OR ANY.

Ivan @ Southwest Speed 03-24-2010 12:06 AM

Nice work!! Next time, resize them pics....lol Nice for close ups though!

Thanks!,
Ivan :thumbsup:

Santos 03-28-2010 02:17 PM

What is the gasket that has to be cut 4 & 8 inches where is it it's not in my kit

ss1_2010 03-29-2010 09:30 PM

I have logged over 20,000 miles for Vararam so far and we worked out alot of kinks and I was highly impressed with the unit.

Camarorss350 03-31-2010 01:09 PM

whats the physical differences in the "tune" and "no tune models"??

ss1_2010 03-31-2010 07:10 PM

no physical just internal

Camarorss350 04-01-2010 09:56 AM

Quote:

Originally Posted by ss1_2010 (Post 1661309)
no physical just internal

ok, so what are the differences lol?

Camarorss350 04-02-2010 07:07 AM

i guess none lol?

Camarorss350 04-06-2010 09:47 AM

Quote:

Originally Posted by Camarorss350 (Post 1667877)
i guess none lol?

Started another thread, looks like its just different filter sizes... smaller for no tune, bigger for tune...

Tech 04-23-2010 12:38 PM

puttin mine in sunday...pumped! thanks for the colored photos!


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