In this project, we're going to install a Cold Air Intake (CAI) kit. Your first question might well be: Why? Well, there are a few potential benefits from doing this. Overall, the idea is to allow the engine to breate more easily by removing air flow restrictions that are evident in the factory-stock system.

Now, these restrictions are real and, depending on your vehicle, can add up to a lot of power loss. A couple of years ago, I was at a local club dyno session. One of the members showed up with a brand new '03 Cobra. The car was run on the chassis dyno and, for the second run, the air intake was disconnected from the throttle body. In essence, all restriction was removed from the engine's ability to draw air in. The difference was quite impressive, because the car showed a gain of forty horsepower between the two runs. In fact, not all of this was directly due to removing the intake, but the largest part of it was.

There are two primary sources of flow restriction; the air filter and the intake silencer. Any CAI kit on the market will remove both of these. The big gains come from replacing the standard air filter with a low restriction version, such as those made by K&N Air Filters. As a side benefit, depending on the kit you use, you will also end up with some much better looking underhood components.

For our purposes, we're going to install a CAI on our 2003 Mach I Mustang, but much of the information applies to other models. The kit we're using comes from Mustang Racing Technologies (MRT), which is run by Scott Hoag. Since Scott was the chief engineer at Ford on the Bullitt and Mach I Mustang projects, we're pretty confident that things should go well.

The MRT kit consists of three main parts; the airbox, the intake tube and a K&N air filter. The airbox will be attached to the fender and draws air from outside the engine compartment. The nicely finished intake tube connects the air box to the throttle body.

The installation process begins with removal of the existing intake system. Opening the current air box, as if removing the filter, allows the intake to be separated into two main sections. The upper section can be removed after loosening the clamp at the throttle body. An 8mm wrench or socket is needed to remove a bolt that holds the lower section to the fender.

With the lower section out, it is important to look for two rubber grommets. They may be in the fender apron or they may have come out with the intake. If the latter is the case, remove and keep the grommets handy. You may want to do some cleanup, as much more of this area is likely to be visible after the CAI installation than it was before.

Some disassembly of the intake will be required in order to separate the MAF (Mass Air Flow) sensor, which is installed in the new intake. For the Mach I, the MAF bolts directly on to the air box. Other systems may use other means to join upper and lower tubes to the MAF.

With the MAF installed, the air box can be placed in the fender with the rubber grommets placed in their original positions. Loosening all of the hose clamps is important in order to get the most adjustability from the components.

Taking your time at this stage is also important, as you need to ensure that there is enough clearance between the intake components and the strut tower. The engine will "rock" during spirited acceleration and the intake tube can contact the body metal. Clunking noises and eventual wear of paint are the minimum troubles that can be expected.

Once everything is lined up, the filter can be installed and the air box closed up. Take a few minutes to double check your work and make sure that all hose clamps are tight, the MAF electrical connector is in place and the PCV hose is connected to the intake tube.

Now, take your steed out for a test drive. Check for driveability issues, such as stalling during a stop or stumbling on acceleration. Either could indicate that some of your work needs to be checked again. You will notice more air intake noise. This is normal, because one of the components we removed was the intake silencer.

Other CAI kits can have a different configuration from the one shown here and may require fewer or more steps. Another common arrangement places the air filter out in the fender itself. Instructions for this type of kit typically have you installing the filter after everything else is done. The result is that you are working from under the car, inside the wheel well, and the chore is quite difficult.

With this type of kit, you may find that it is possible to build up a subassembly of the lower filter, lower intake tube and the fender plate... essentially everything from the MAF out. Take your time and think about what you need to do before rushing ahead, or throwing something out the window.

Finally, if you plan to install a strut tower brace, or already have one in place, there could be interference issues between the brace and the CAI. Verify with the brace supplier or check around on internet message boards to see if someone else has previously installed the combination you have in mind.

Disclaimer

Yep, you got it. If you try this and it goes poorly, don't get mad at us. Don't even think of asking us to pay for your mistakes. We've done this mod ourselves and everything went swimmingly. This article is presented for your information and entertainment purposes only. If you don't have the right tools or don't fully understand the instructions, get somebody more knowledgeable to help you. Absolutely and at all times, be sure that you are doing the work safely!