Parts Needed
Blow Off Valve (HKS SSQV, Tial etc.....)
Blow off Valve Flange (Aluminum or Steel, can be found on ebay)
Aluminum or Steel Pipe depending on what flange you buy (about 6"- 8" long and an Outside Diameter of 2.33")
1 foot of standard vacuum hose
Vacuum line Y-tube (only if you plan on running CBV & Blow off Valve together)
2, 2 1/2" T Clamps (can be found at Hydraulic supply store)
Heat shrink tubing (optional)
Before you do anything
to the car you are going to need to get a 2.33" outside diameter pipe.
http://www.onlinemetals.com/ is where I purchesed mine and
had it turned down by a machine shop for an exact fit. You will
also need to drill a hole the size of the
inside diameter of your flange in your pipe where the flange is going
to be welded.
Will look like this when finished.
With the flange welded
on your pipe install your Blow off Valve on the flange. Keep
in mind if you are installing your Blow off Valve on the turbo piping
right before the intake you are going to want the Blow off Valve to sit
parallel with your pipe. Remove the air duct Bolts (all 10mm as
shown below) Now gently pull the air duct towards the motor and
out.
Now that the air duct is out of the way there are three 10mm bolts
holding the air filter box in place, remove them. Next loosen the air
intake hose clamp located just above the air filter box, while you are
there disconnect the air flow sensor located between the hose clamp you
just loosened and the air filter box.(As shown below)
Pull the air
filter box out of the air intake hose, as you lift the air Filter box
there is a group of 3-4 hoses attached to the bottom of the box just
unclip them and lift the air filter box out.
Now that you can get
to the turbo piping this is where it gets tricky. You
need to make your first cut just below the intake manifold with your
hacksaw, sawzall, or razor knife. Whatever you can cut
with in a tight space since there is not a lot of room to work!.
Once
you have made the first cut you can loosen the hose clamp where the
turbo piping connects to the inter-cooler and the hose clamp on the
small hose in the middle of the pipe (as shown below) and the whole
thing should lift right out.
Now that you have the turbo piping out you are
going to cut 3-4 inches (depending on the size of your Blow off Valve
Flange) off the end you just cut. Make sure to take a file and
remove any rough edges from the cuts you just made. Also take a clean
rag and wipe out any plastic debris inside your piping before
re-installing it.
Put the T-Clamps on
the turbo piping (make sure you position the nuts on both clamps facing
up, so you can get to them once you put the pipe back in the car)
Now insert one end of your pipe with the Blow off Valve welded on it
into the pipe you just cut the 3-4 inches off of earlier. Make
sure the actual Blow off Valve hangs below the turbo piping. If you put
it on top when you go to put the pipe in the car the Blow off Valve
will hit the intake manifold, there is not enough room. Tighten
the T-clamp down to where the Blow off Valve assembly is tight but can
still move a little. Plug
the other end of your Blow off Valve pipe into the turbo piping on the
car, reconnect the other end to the inter-cooler and tighten the hose
clamp. Before you forget, reconnect that small hose and hose clamp you
took off earlier as shown below.
Now that all the turbo piping is in the car with the Blow off valve in
between you can move the Blow off Valve assembly to where you want it
(make sure the back of your Blow off Valve isn't hitting the motor) and
tighten your T-Clamps down nice and snug. Make sure everything is tight
and grab the turbo piping and shake it a few times to ensure its tight and will not come apart under boost.
Now your Blow off Valve is installed but now you need to connect your
vacuum line(s) If you want to run your stock CBV and your newly
installed Blow off Valve at the same time this is what you do!
Disconnect the CBV vacuum line from the intake manifold. Next install a 2 inch piece of vacuum line with a Y tube
And connect the CBV vacuum line and a Vacuum line from the HKS to the Y-tube
Finally connect the vacuum line to your Blow off Valve.
If you
just want to run your Blow off Valve only than you would just take a
piece of vacuum line from the intake manifold straight to the blow off
valve! Like this.
Reinstall air filter box making sure to reconnect everything you disconnected earlier.
Finally
once everything is back together start the engine and check to make
sure everything looks tight and you have no leaks or problems.
