(NOTE: BEFORE YOU ORDER YOUR PART, CHECK FOR THE APPROPRIATE NUMBER OF HOSE ATTACHMENT POINTS - IE... charcoal can vent, valve cover vent return, BOV return...)
One of the first upgrades in the tuner market is the intake piping and filter. Its like the Holy Grail to a Honda owner. It may not be quite the same in the DSM world with the turbo limiting the cool "wwwwwwoppp" sound they all strive so hard to get; but its still a worthy upgrade if you plan on taking your boost past the realm of stock.
Here's a quick look at my install of a Dejon 1G Curved Intake on my 90 GS-T. Its a pretty straight forward install, I did however run into a few bumps along the way. I hope you find something helpful...
PARTS
* Dejon Intake (The short one not the one that goes to the fire wall)
* BOV piping (pick something up at the auto parts store)
* 3" to a 2.5" coupler (Specter Hose Coupling will work good)
TOOLS
* 8mm socket (for the hose clamps)
* Tape measure & pencil
* Dremal tool (2 or more steel cutter disks, 1/2" drum sander bit, eye protection)
* Razor blade (one with a handle is best)
* Spray paint (I used a high temp flat black)
#1 Make sure to read up on your parts before you make your purchase. You don't want to end you on delivery day with a part thats for a different set up that the one you have!
#2 Once you have your intake keep it in its protective rap; go out to your car and give it a good look over. You'll want to move your old intake out of the way to make sure it fits. Even if its the right part it may not go in easy. The worst thing to do is cram the pipe in your engine bay, scratching it all to hell; only to fined its not the one you want. If its still wrapped in its original packaging and your careful you can at least say it was never installed. NOTE: GOOD LUCK RETURNING PARTS!!!
#3 As I said before the part may need some convincing to get it in the right spot for the install. I'm installing my intake to a "big Evo III 16G" with a Dejon upper inter-cooler pipe setup. Your install may vary according to your cars turbo and piping. On the intake side of the 16G there's not enough room for the clamps to fit over the rubber coupling that is supplied from Dejon to mount the intake to the turbos inlet. With the 3" piping I ordered and the way the waist gate bolts to the turbos intake housing there's not much chance to use these three rubber pieces to transition from the 3" intake pipe down to the Evo III's 2.25" intake face.
#4 To fix this I traded the three rubber rings for a nice 3" dropping down to 2.5" coupling from my local part store. Since I went with the new coupler, this lengthened the hole intake by about 2". Later I would fined out this would not give me enough room to clear the filter past the upper inter cooler and its outlet piping attachment point. So to save you this hassle, you should go ahead and shave the new coupling down as much as possible to gain back this space. I used a razor blade to cut the coupling, and used a clamp band in the spot I wanted to cut to help me with a straight line. Then sanded the cut smooth with my Dremal and sanding drum. To get the coupling to slide on to the intake pipe and get the most clearance, I put a round notch in the couplings edge about 3/4" deep on the 3" side. This will help accommodate the blow off valve return piping welded to the intake pipe on this end. You can order the intake from dejon with or without the return piece or any other fitting needed.
#5 Now that you have the stock intake out of the car, make sure and do all the free-mod upgrades you can if not done already. You can find them in the DSM tech guide; under upgrade paths. Most of my free-B's have already been done; however I did have to cut my air can down further to fit every thing just right. You may be able to stuff it all in with out this step. If you go with the supplied three rings instead of the 3" to 2.5" coupler, I'm sure your going to have trouble.
With everything together, place the intake in the engine bay were it will need to go. Measure the length of the Dejon intake piping with the new 3" to 2.5" coupling and filter can bolted together starting at the turbos inlet. Make sure you will have room for what you are planning. With that length in mind, draw out your cut lines on the side of the can. This will let you see what you thinking in your minds eye and help you keep a straight line wile cutting. Note how the can is going to mount to the car. Before cutting into your air can, also note the tabs that are used to align the three parts together. The two halves of the can and the filter insert. Use those to keep everything in the right spots when planning your cut. The owner before me threw out the top piece of my air can and clamped the bare fasteners down on the air filters rubber gasket (not recommended with a $50 aftermarket filter you plan to reuse). The top piece I'm using was out of a 1.8L and does not mount to anything in mt engine bay. Without anything to bolt to, I left a good five inches on the back bottom side facing the engine of the can to support the filter resting on the body of the car engine compartment. I would recommend something similar to this to support the can and help block the heat form the engine.
After cutting i used the drum sander to make everything as strait as possible. Sanded around the edges removing any sharp pieces of metal that may be left. Once finished this is a good time to wash any metal shaving and grime for both the inside and out side of the air can.
Any time I take a part off the car it has to be clean to go back on, it just me.
cutting and grinding the can left some scratches and unpainted edges. to fix this I used Dupli-Color's 500*F engine enamel in a flat black. I think the flat finish matches the engine bay better. Make sure and tape off any thing not safe to paint. I removed the inside parts from the metal housing of the can. You don't want any paint to get on the MAS (mass air flow sensor).
#6 With the Dejon upper intake pipe installed earlier I was really at a loss for room to place the intake. On the air cleaner side of the intake pipe, I used my Dremal and a steel cutting disk to remove about 3/4 of a inch band of piping from the filter side of the intake. There was plenty of room to do this and still seat the rubber coupler to the air can with out leaks. The black coupling supplied with the kit did this great and looks almost as good as the red coupling I had to add to the turbo side earlier in the install.
#7 It was easier than I though to find something to hook up the blow off valve to the intakes return pipe. I'm not sure if the stock rubber return line will work in this set up; as I am with out mine. I hacked up my stocker years ago doing a "Home Depot" upper IC pipe. Luckily its fairly easy to match the size and length needed at the local auto part stores back supply room. I used a 1 1/4" diameter radiator hose that cost $12. You'll be surprised how many hoses there are to chose from and their low prices. Be sure to check cost on more that one piece. Similar shapes can vary allot from hose to hose. To get the right one use a bent coat hanger to track the length and bends you need along through your engine bay between the BOV and the return pipe. Be sure to take the hanger in the store with you to size up the one that could fits best.
After a little sweat. I had a bad ass Dejon intake that accents the red on my engine. This upgrade should add some room for increased airflow down the road. The best part of all, it fits perfect and looks killer, and was all done at home. This was a smooth install even with the mods I had to do, you should have no problems as long as you have the right tools and use your head. Make sure to wear safety goggles when grinding, you'll be reminded quick if you don't.
Hope the pic's help you... Good luck, 90gst_sean.
One of the first upgrades in the tuner market is the intake piping and filter. Its like the Holy Grail to a Honda owner. It may not be quite the same in the DSM world with the turbo limiting the cool "wwwwwwoppp" sound they all strive so hard to get; but its still a worthy upgrade if you plan on taking your boost past the realm of stock.
Here's a quick look at my install of a Dejon 1G Curved Intake on my 90 GS-T. Its a pretty straight forward install, I did however run into a few bumps along the way. I hope you find something helpful...
PARTS
* Dejon Intake (The short one not the one that goes to the fire wall)
* BOV piping (pick something up at the auto parts store)
* 3" to a 2.5" coupler (Specter Hose Coupling will work good)
TOOLS
* 8mm socket (for the hose clamps)
* Tape measure & pencil
* Dremal tool (2 or more steel cutter disks, 1/2" drum sander bit, eye protection)
* Razor blade (one with a handle is best)
* Spray paint (I used a high temp flat black)
#1 Make sure to read up on your parts before you make your purchase. You don't want to end you on delivery day with a part thats for a different set up that the one you have!
#2 Once you have your intake keep it in its protective rap; go out to your car and give it a good look over. You'll want to move your old intake out of the way to make sure it fits. Even if its the right part it may not go in easy. The worst thing to do is cram the pipe in your engine bay, scratching it all to hell; only to fined its not the one you want. If its still wrapped in its original packaging and your careful you can at least say it was never installed. NOTE: GOOD LUCK RETURNING PARTS!!!
#3 As I said before the part may need some convincing to get it in the right spot for the install. I'm installing my intake to a "big Evo III 16G" with a Dejon upper inter-cooler pipe setup. Your install may vary according to your cars turbo and piping. On the intake side of the 16G there's not enough room for the clamps to fit over the rubber coupling that is supplied from Dejon to mount the intake to the turbos inlet. With the 3" piping I ordered and the way the waist gate bolts to the turbos intake housing there's not much chance to use these three rubber pieces to transition from the 3" intake pipe down to the Evo III's 2.25" intake face.
#4 To fix this I traded the three rubber rings for a nice 3" dropping down to 2.5" coupling from my local part store. Since I went with the new coupler, this lengthened the hole intake by about 2". Later I would fined out this would not give me enough room to clear the filter past the upper inter cooler and its outlet piping attachment point. So to save you this hassle, you should go ahead and shave the new coupling down as much as possible to gain back this space. I used a razor blade to cut the coupling, and used a clamp band in the spot I wanted to cut to help me with a straight line. Then sanded the cut smooth with my Dremal and sanding drum. To get the coupling to slide on to the intake pipe and get the most clearance, I put a round notch in the couplings edge about 3/4" deep on the 3" side. This will help accommodate the blow off valve return piping welded to the intake pipe on this end. You can order the intake from dejon with or without the return piece or any other fitting needed.
#5 Now that you have the stock intake out of the car, make sure and do all the free-mod upgrades you can if not done already. You can find them in the DSM tech guide; under upgrade paths. Most of my free-B's have already been done; however I did have to cut my air can down further to fit every thing just right. You may be able to stuff it all in with out this step. If you go with the supplied three rings instead of the 3" to 2.5" coupler, I'm sure your going to have trouble.
With everything together, place the intake in the engine bay were it will need to go. Measure the length of the Dejon intake piping with the new 3" to 2.5" coupling and filter can bolted together starting at the turbos inlet. Make sure you will have room for what you are planning. With that length in mind, draw out your cut lines on the side of the can. This will let you see what you thinking in your minds eye and help you keep a straight line wile cutting. Note how the can is going to mount to the car. Before cutting into your air can, also note the tabs that are used to align the three parts together. The two halves of the can and the filter insert. Use those to keep everything in the right spots when planning your cut. The owner before me threw out the top piece of my air can and clamped the bare fasteners down on the air filters rubber gasket (not recommended with a $50 aftermarket filter you plan to reuse). The top piece I'm using was out of a 1.8L and does not mount to anything in mt engine bay. Without anything to bolt to, I left a good five inches on the back bottom side facing the engine of the can to support the filter resting on the body of the car engine compartment. I would recommend something similar to this to support the can and help block the heat form the engine.
After cutting i used the drum sander to make everything as strait as possible. Sanded around the edges removing any sharp pieces of metal that may be left. Once finished this is a good time to wash any metal shaving and grime for both the inside and out side of the air can.
Any time I take a part off the car it has to be clean to go back on, it just me.
cutting and grinding the can left some scratches and unpainted edges. to fix this I used Dupli-Color's 500*F engine enamel in a flat black. I think the flat finish matches the engine bay better. Make sure and tape off any thing not safe to paint. I removed the inside parts from the metal housing of the can. You don't want any paint to get on the MAS (mass air flow sensor).
#6 With the Dejon upper intake pipe installed earlier I was really at a loss for room to place the intake. On the air cleaner side of the intake pipe, I used my Dremal and a steel cutting disk to remove about 3/4 of a inch band of piping from the filter side of the intake. There was plenty of room to do this and still seat the rubber coupler to the air can with out leaks. The black coupling supplied with the kit did this great and looks almost as good as the red coupling I had to add to the turbo side earlier in the install.
#7 It was easier than I though to find something to hook up the blow off valve to the intakes return pipe. I'm not sure if the stock rubber return line will work in this set up; as I am with out mine. I hacked up my stocker years ago doing a "Home Depot" upper IC pipe. Luckily its fairly easy to match the size and length needed at the local auto part stores back supply room. I used a 1 1/4" diameter radiator hose that cost $12. You'll be surprised how many hoses there are to chose from and their low prices. Be sure to check cost on more that one piece. Similar shapes can vary allot from hose to hose. To get the right one use a bent coat hanger to track the length and bends you need along through your engine bay between the BOV and the return pipe. Be sure to take the hanger in the store with you to size up the one that could fits best.
After a little sweat. I had a bad ass Dejon intake that accents the red on my engine. This upgrade should add some room for increased airflow down the road. The best part of all, it fits perfect and looks killer, and was all done at home. This was a smooth install even with the mods I had to do, you should have no problems as long as you have the right tools and use your head. Make sure to wear safety goggles when grinding, you'll be reminded quick if you don't.
Hope the pic's help you... Good luck, 90gst_sean.
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