Volant CAI install / DIY
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Joined: May 2012
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From: San Antonio, TX
Volant CAI install / DIY
I couldn't find a comprehensive DIY for the Volant CAI kit and thought I'd take a try.
I ordered the kit online through http://www.newlevelmotorsports.com/ it arrived in five days. I unboxed the kit and made sure it had everything I needed.
For tools, I used my Kobalt screw driver from Lowes which has two sizes of nut drivers built in. One size fits the nut on the metal bands which is easier then using a flat head. This was the only tool I needed to remove the stock system. For the install I needed a 1/2" socket and a 7/16" wrench.
1. Disassembly: Just loosen all the metal straps, un-screw the one bolt (I used my kobalt nut driver as seen in one of the attached photos), disconnect the electrical connection for the air sensor, and disconnect the manifold vacuum hose. Once you have all this done you can pull the plenum space away from the engine intake. Pull the plenum and hose away from the air box.
2 Stock air box: Open and remove the top, remove the air filter, and pull up firmly on the remaining box. You must also remove the stock air inlet at the front of the hood, at this point it will simply pull out but there is one catch, the rubber seal has a tiny trim connector keeping it attached to that stock inlet. I found it easier to remove the trim connector from the rubber seal then carefully remove it from the plastic piece with a pair of pliers - you will need to re-use this part along with one of the rubber grommets on the bottom of the stock air box - again, simply pull this out.
3. Air sensor: Remove it from the stock tube and install it in the Volant air tube. There is a tab on the sensor, use your finger nail to overcome the catch and only 1/4 turn till it's loose, jiggle it a little while gently pulling on it to remove it. Install in the new system is easier. On the Volant air tube, insert the sensor into the pre-installed rubber grommet located on the Volant air tube. Gently twist it back and forth into the grommet while holding the edge of the grommet with your other thumb. Insert it until the little tab touches the rubber grommet. I installed it with the same orientation as the stock air tube.
4. Now to install the rubber couplers and air tube. Place a smaller, size 56, metal band around the smaller end of the reducing coupler and slide it over the intake then orient and tighten the metal band. I oriented the rubber tube with the Volant Logo side up. Slide a larger metal band, size 64, around the larger end. Now slide the Volant air tube into place, short end toward the engine intake and long end towards where the stock air box was. At this point don't tighten the metal band.
5. Install the new air box: Using a 1/2" socket loosen the power steering reservoir pushing it over about an inch and a half - and save the bolt. Insert the rubber grommet recovered from the stock air box on the Volant pre-drilled bottom hole of the Volant box. There is a second hole on the front of the Volant box but I don't know what this is for. Slide the Volant air box into place being careful to route the front rubber seal over the intake port then snap the box onto the OEM grommet mount by pressing firmly down. I found it useful to peer into the right side of the box down to where the mount is so I could be sure I was in the right position.
6. Linking the Box and the air tube: Using the remaining two metal bands, slide them over the two ends of the remaining coupler. Slide one end over the air tube and one end over the air box - you may need to pull the box back off the grommet mount to give you enough room to make the coupler fit. Once everything is fitted together orient the two metal bands and Volant logo then tighten all bands (even the one from step 4).
7. Okay, here's the tricky part: For the bracket that is supplied by Volant you are supposed to mount it to the steering fluid reservoir. The catch is it doesn't fit. You can modify it by cutting it and drilling your own hole - this is what I did. Once I modified it the space is too tight and I ended up dropping the supplied Volant bolt (with 7/16” head) and since the box is in there solidly already I just said F#!$ it and left it. I was able to mount the Power Steering reservoir back with no issue. The grommet mount on the bottom coupled with the air hose and the lip on the mount for the reservoir is enough to keep it from jiggling too far. I tried calling Volant support but good luck with that - they have weird hours and even though I called before their "lunch break" no one answered my call and there is no voice mail.
8. Connect the electrical connector for the air sensor.
I plan to make a video of the before and after but that will have to wait until I have more time.
here's a video on what the cockpit sounds like once installed:
http://youtu.be/NbRCJBMMoMw
I ordered the kit online through http://www.newlevelmotorsports.com/ it arrived in five days. I unboxed the kit and made sure it had everything I needed.
For tools, I used my Kobalt screw driver from Lowes which has two sizes of nut drivers built in. One size fits the nut on the metal bands which is easier then using a flat head. This was the only tool I needed to remove the stock system. For the install I needed a 1/2" socket and a 7/16" wrench.
1. Disassembly: Just loosen all the metal straps, un-screw the one bolt (I used my kobalt nut driver as seen in one of the attached photos), disconnect the electrical connection for the air sensor, and disconnect the manifold vacuum hose. Once you have all this done you can pull the plenum space away from the engine intake. Pull the plenum and hose away from the air box.
2 Stock air box: Open and remove the top, remove the air filter, and pull up firmly on the remaining box. You must also remove the stock air inlet at the front of the hood, at this point it will simply pull out but there is one catch, the rubber seal has a tiny trim connector keeping it attached to that stock inlet. I found it easier to remove the trim connector from the rubber seal then carefully remove it from the plastic piece with a pair of pliers - you will need to re-use this part along with one of the rubber grommets on the bottom of the stock air box - again, simply pull this out.
3. Air sensor: Remove it from the stock tube and install it in the Volant air tube. There is a tab on the sensor, use your finger nail to overcome the catch and only 1/4 turn till it's loose, jiggle it a little while gently pulling on it to remove it. Install in the new system is easier. On the Volant air tube, insert the sensor into the pre-installed rubber grommet located on the Volant air tube. Gently twist it back and forth into the grommet while holding the edge of the grommet with your other thumb. Insert it until the little tab touches the rubber grommet. I installed it with the same orientation as the stock air tube.
4. Now to install the rubber couplers and air tube. Place a smaller, size 56, metal band around the smaller end of the reducing coupler and slide it over the intake then orient and tighten the metal band. I oriented the rubber tube with the Volant Logo side up. Slide a larger metal band, size 64, around the larger end. Now slide the Volant air tube into place, short end toward the engine intake and long end towards where the stock air box was. At this point don't tighten the metal band.
5. Install the new air box: Using a 1/2" socket loosen the power steering reservoir pushing it over about an inch and a half - and save the bolt. Insert the rubber grommet recovered from the stock air box on the Volant pre-drilled bottom hole of the Volant box. There is a second hole on the front of the Volant box but I don't know what this is for. Slide the Volant air box into place being careful to route the front rubber seal over the intake port then snap the box onto the OEM grommet mount by pressing firmly down. I found it useful to peer into the right side of the box down to where the mount is so I could be sure I was in the right position.
6. Linking the Box and the air tube: Using the remaining two metal bands, slide them over the two ends of the remaining coupler. Slide one end over the air tube and one end over the air box - you may need to pull the box back off the grommet mount to give you enough room to make the coupler fit. Once everything is fitted together orient the two metal bands and Volant logo then tighten all bands (even the one from step 4).
7. Okay, here's the tricky part: For the bracket that is supplied by Volant you are supposed to mount it to the steering fluid reservoir. The catch is it doesn't fit. You can modify it by cutting it and drilling your own hole - this is what I did. Once I modified it the space is too tight and I ended up dropping the supplied Volant bolt (with 7/16” head) and since the box is in there solidly already I just said F#!$ it and left it. I was able to mount the Power Steering reservoir back with no issue. The grommet mount on the bottom coupled with the air hose and the lip on the mount for the reservoir is enough to keep it from jiggling too far. I tried calling Volant support but good luck with that - they have weird hours and even though I called before their "lunch break" no one answered my call and there is no voice mail.
8. Connect the electrical connector for the air sensor.
I plan to make a video of the before and after but that will have to wait until I have more time.
here's a video on what the cockpit sounds like once installed:
http://youtu.be/NbRCJBMMoMw
Thread Starter
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Professional
Joined: May 2012
Posts: 109
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From: San Antonio, TX
Oh, yeah, $#!t, forgot to mention that... I disconnected mine but not because of this mod - I put a 15Lb racing battery in while waiting for the paint to dry on my modified bracket. I don't personally believe you need to perform a reset, this is my fourth CAI install and I haven't had to do a reset in the past on other brand vehicles. It can't hurt so if you're up to doing it go ahead.
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Joined: Mar 2012
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From: Old Bridge,NJ
Oh, yeah, $#!t, forgot to mention that... I disconnected mine but not because of this mod - I put a 15Lb racing battery in while waiting for the paint to dry on my modified bracket. I don't personally believe you need to perform a reset, this is my fourth CAI install and I haven't had to do a reset in the past on other brand vehicles. It can't hurt so if you're up to doing it go ahead.
Thread Starter
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Professional
Joined: May 2012
Posts: 109
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From: San Antonio, TX
Pictures
Video's up with more detailed photos - gotta love my Mac. Here's a youtube link: http://youtu.be/F2ATJSkwv-w
Last edited by safford197; May 22, 2012 at 02:09 AM.
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Well done on the write up. Additionally, if anyone cares to do what I did, I just cut the mounting bracket in half (on the long end) and then mounted in only the side for the fluid reservoir perch. This made it so the air box on the Volant CAI rests snugly up against the bracke itself...no wiggle at all.
Additionally, I've sent photos of the issue to the folks at Volant and they are actively working to identify a suitable bracket to include in future install kits for the 3rd gen D.
Hope this helps...and I agree that this sounds really good. And, it only gets better!
Additionally, I've sent photos of the issue to the folks at Volant and they are actively working to identify a suitable bracket to include in future install kits for the 3rd gen D.
Hope this helps...and I agree that this sounds really good. And, it only gets better!