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How To Build Your Own Air Intake System

Submitted by: Bruce Simmons

Air intake systems help give your PT a bit more horsepower by increasing the airflow to the combustion chamber. There are many air intake systems on the market and all of them ranging in cost of $150.00 or more. Here is an inexpensive alternative to getting the same results but at a third of the cost.

I looked over the alternative air intake examples listed on PT Do It Yourself and decided to use some of the same ideas, but end up with more of an OEM look. Here's my variation of the air intake modification.

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Parts:

• 1 ea. K&N cylindrical air filter (P/N RU-0620)
• 1 ea. Exhaust Elbow, 2-1/4;" OD 90 Degree galvanized steel (P/N 548704)
• 1 ea. Mighty Flow, 3-1/8" (D) x 24" (L) air intake hose (P/N 96062)

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Procedure:

1. Remove the OEM air box assembly by loosening the OEM hose clamp that connects it to the air intake hose. Leave this clamp on the air intake hose; you will reuse it later on in the procedure. (Photo #1.)
2. Remove the base of the air box assembly by pulling upwards until it pops out of place.
3. Loosen (slightly) the remaining OEM air intake hose clamp at the throttle body. You will use this later to adjust the angle of the assembly. Take the 90 degree exhaust elbow and carefully insert it into the OEM air intake hose about 3 inches; avoid shoving it into the IAT Sensor. (Photo #2.) Then tighten the hose clamp onto the exhaust elbow.
4. Next, take the new 3-1/8" D air intake hose and slid it onto the 90 degree exhaust elbow you just installed. Leave this hose loose on the elbow for now.
5. Loosen the clamp that is furnished with the K&N filter and slide the filter onto the open end of the exhaust elbow approximately 2 to 3 inches. (Photo #3.) Tighten the clamp slightly to hold the filter onto the elbow, but allow enough play to move the filter on the elbow. You can now adjust the angle of the OEM air intake hose downward a few degrees and adjust the filter correctly on the elbow. Once you are satisfied with the positioning, tighten all three hose clamps.
   Note - Do not insert more than 2 to 3 inches of the elbow inside the K&N filter, otherwise you will block off the inside of the element and dramatically reduce the air flow from the filter.
6. Once the clamps are tight take the 3-1/8" air intake hose that is loose on the elbow and move it up and over the hose clamp on the OEM air intake hose. The 3-1/8" air intake hose has plastic snap clamps that will clamp around the OEM intake hose. (You may want to place a small piece of duct tape over the screw of hose clamp on the OEM air intake since this may eventually pierce the new hose.).
7. Next, stretch the hose over the entire length of the exhaust elbow; then pull it over the hose clamp on the K&N filter. Again, close the plastic snap clamps on this hose. (Photo #4.)
8. The assembly was so rigid that I chose not to use any kind of hanger to keep the filter in place. I did however place a 4" x 4" section of a Scotch Brite pad under the filter to keep it from wearing a hole in the filter. The very porous pad will allow air to circulate under the filter.

This assembly takes advantage of the cooler air around the filter and the plastic 3-1/8" air intake hose keeps a dead air space between the exhaust elbow and the hot engine compartment. Since plastic is a poor conductor of heat, it insulates the intake (somewhat). Since there is a space between the exhaust elbow and the 3-1/8" air intake hose, I plan on wrapping thin insulation around the exhaust elbow, which will be covered by this air intake hose.

I have noticed a small increase in fuel economy, and the PT seems a little quicker, but it really sounds great when you accelerate.

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Notes

I purchased the exhaust elbow at Discount Auto Parts for $3.87.

Photo 1

Photo 2

Photo 3

Photo 4

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