ZRE Custom CAI DIY

[Ascendant Rice]

Hey guys thought i should write up a guide to make a custom CAI for the ZRE!!

This is my first time writing a guide so sorry if its a bit hard to understand, if you have any questions ask and ill answer it the best i can :)

Firstly to be able to make this intake you need to have the ZRE that comes with the 2 piece air box otherwise you most likely have to mutilate your air box or buy a MAF mount.

What you will need:

1x 3" 90degree bend pipe (Plastic or aluminium, can be bought from repco or super cheap)

1x 3" 60degree bend (plastic pref, bought mine from repco)

2x 2"rubber pipe joiners/connectors (can be bought from repco)

1x Pod filter of your choice with a 3" neck (i used a 3A Racing pod)

5x 4" or bigger hose clamps

Set of tools ( flat head screw driver and sockets)

Cable ties can be used to make a bracket for the intake so it doesn't move around

Once you got all that you need we can begin :)

Firstly you will need to remove your front bar (You will need a socket wrench for this)

Next, remove your stock air box and resonator from the car but leave the sensor mount on (after you remove the 2 bolts it should pop straight out of the box, if you have the 2 piece zre airbox. if not you will need to either cut it off or get an after market mount)

next, get your Pod and attach it one side of your 90degree bend and use a hose clamp to make sure it wont come off then get one of your rubber connectors and put it on the other side of the pipe and clamp it down aswell then put it aside.

next, get your remaining rubber connector and stretch it so it fits onto the MAF sensor mount then use a hose clamp to secure it tightly to the adapter

next, take your 90 degree pipe and pod and and feed it through the gap between your battery and and fuse box on the ride front side of your car

next, grab your 60 degree bend and and put it between the maf mount and the 90 degree bend and connect it to the rubber connectors and clamp it so it stays on tight. you will need to bend the hose that's connected to the throttle towards the battery (dont worry the pipe is flexible and has bendy join so it wont hurt the pipe or air flow) end result should look like this

now you can use cable ties to make it sit nice and snug so it doesnt rattle. Here is a video i made that talks about the intake.

Before you put the front bar back on take it for a test drive if done correctly you wont get an engine light :) after the test drive if its all good put your front bar back on and your done, you now have a cold air intake enjoy!!! :)

EDIT: i have driven over 10,000 KM without any dramas or engine lights!!!! Originally instead of the 60degree bend i used a straight pipe but this caused a few problems 1. it didnt join the 90degree bend and the sensor adapter together that well and tended to come loose and pop off 2. made air flow a bit turbulent so thats why i changed it to a 60 degree bend.

Thanks to Wy (GTL05T) for helping me make this intake!!!

Here are a few sound clips of the CAI in action.

Edited September 30, 2010 by Ascendant Rice

[Ascendant Rice]

[Ascendant Rice]

[RedSportivo]

Thanks Heaps!

Btw This works for sportivo engines rite?

Edited September 30, 2010 by RedSportivo

[dutchie101]

Well done man! Thanks for the guide

[Ascendant Rice]

Thanks Heaps!

Btw This works for sportivo engines rite?

This guide is for the 2zrfe engine, though im pretty sure if you had the right pipes and a maf mount you could do this to a sportivo. looking at pictures of the stivo engine bay you would probably need maybe 3 more additional pipes.

[Branno]

Where can I get a 3a racing pod from? Supercheap?

[johnnieboi]

Where can I get a 3a racing pod from? Supercheap?

No. Try bidding for one on Ebay or purchasing directly from a 3A Racing distributor shop. Ebay might be the cheaper alternative. Make sure its 3" or 75mm neck on the pod filter.

[Branno]

They have one on there which is sitting at $0.95 so I'm keeping an eye on it. (stay back, it's mine)

[Ascendant Rice]

They have one on there which is sitting at $0.95 so I'm keeping an eye on it. (stay back, it's mine)

is it this one?

[Branno]

No, it's not, is that the one with heat shielding? Did you use intercooler piping for your pipes? I'm thinking of doing it next weekend. I'll post up photos afterwards.

[Ascendant Rice]

No, it's not, is that the one with heat shielding? Did you use intercooler piping for your pipes? I'm thinking of doing it next weekend. I'll post up photos afterwards.

good this pod is crap! yeah i did use intercooling pipe

[Branno]

What are the lengths of your silicone and rubber joiners?

[Ascendant Rice]

What are the lengths of your silicone and rubber joiners?

not sure i just got the standard size.

[juvenile]

Does this piping serve any purpose seeing it has the factory air box, or is it just for show?

[dutchie101]

Looks maybe like a larger diameter n(maybe 1/4"), but i dont think there would be much gain.. Bloody neat work tho.

[juvenile]

Looks maybe like a larger diameter n(maybe 1/4"), but i dont think there would be much gain.. Bloody neat work tho.

certainly is a piece of work,I'd swap my SRI for that pipe....

[Ascendant Rice]

i think it makes the air flow smoother than with the silicon hose

[BumBuddy]

About to attempt it this weekend. Any issues or problems after installing this??

Will this install be the same for the 2011 ZRE Corolla Ascent?

Edited January 9, 2012 by BumBuddy

[jeffy]

Probably a cel..?

GOod luck though :)

[pezzie]

Does anyone know how this would be made? i wouldnt mind having some bling in the bay.