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Old 02-26-2005, 02:31 PM   #1
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CAI Question

Just installed my eBay CAI after much procrastination, using the awesome CAI install guide.

Went pretty well, the only issue I am having is that the upper pipe is at such an angle going into the coupler to the TB that one side of the upper pipe is nearly coming out of the coupler. This angle was necessary to make the lower pipe mate correctly with the MAF coupler.

My stupid digital camera is being gay right now so I cant put up a pic. I realize that a picture would prolly be really helpful to answer my question so hopefully I will get this damn thing working again tonight

It feels like it is in there pretty good, as I tightened all the clamps on the lower and the upper really securely, I am just worried that the upper pipe is going to pop out of the coupler when I'm driving along sometime and cause problems.

Do I really need to worry about this?

Also, when I first started the car after installing the CAI there was a whistle on acceleration, which i figured was normal, since most people talk about it. However, I drove around the block and by the time I got home, the whistle was gone. Is that normal, is there a leak or sumthin?

Thanks for the advice.
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Old 02-26-2005, 02:58 PM   #2
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mine doesnt whistle as much once my car is warmed up so thats prob the reason that stopped, about the upper pipe yeah pictures would help so see ifyou can get those up whenever but until then just keep an eye on it
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Old 02-26-2005, 03:22 PM   #3
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Got my camera working, so here are some pics (pardon my dirty engine bay), haven't done my post-winter thourough cleanup yet.

I need to go back and touch up my paintjob on the CAI. I used Anondizit or whatever it is called and it kinda got scratched all to hell during the install.

Also, upon closer listening, I can hear the whistle again. I only hear it when I first press the gas and I don't give it 100% throttle tho. I also think my engine note has changed a bit, but that could just be in my head.

Looking at the finished pics on the CAI article mine doesn't look all that much worse I don't think.

Will mine be ok?
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Old 02-26-2005, 04:12 PM   #4
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Dang man, that TB tube looks like it needs more bend in it!

I got some elbows here that might fit, if so I'd send you one
for shipping only or you could trek over here to T.H. and I'd
put it on... Or help you fix that one. Looks fouled up to me...

Email me and we can exchange phone #'s.
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Old 02-26-2005, 04:16 PM   #5
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Quote:
Originally Posted by RGR
Dang man, that TB tube looks like it needs more bend in it!

I got some elbows here that might fit, if so I'd send you one
for shipping only or you could trek over here to T.H. and I'd
put it on... Or help you fix that one. Looks fouled up to me...

Email me and we can exchange phone #'s.
yeah, it definitely seems like it needs more bend, but I dunno, i mean, it doesn't look much worse than the pics on the CAI install guide.

Does anyone else with a '94-'98 have pics of their upper pipe for comparision?

I might have to take you up on that offer, if everyone else thinks my pipe is screwed too.
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Old 02-26-2005, 04:20 PM   #6
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It is messed up, unless you can rotate it some and get better alignment.
But it looks like you have is as good as possible dude.
Kinda hard to tell from Pix, not being 3-D
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Old 02-26-2005, 04:30 PM   #7
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Oh, look at this pic:

http://www.mustangevolution.com/foru...achmentid=6801


That TB tube looks like it could be moved more into the TB and pulled out
of the MAF coupler a bit. It is cocked 1 way in the MAF end and the other
at the TB. You might need to cut off a bit at the TB end, if it is too long.
It also looked like the tube needed to be inserted further in this pic:

http://www.mustangevolution.com/foru...achmentid=6804


See what I mean?
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Old 02-26-2005, 07:02 PM   #8
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I think I have it fixed, at least for now.

I pulled the lower pipe out of the wheelwell a little more and loosened the coupler between the MAF and the upper pipe and i managed to push the upper pipe into the TB coupler a little further and tightened the bejeezus out of the hose clamp.

I had to run to Meijer's tonight to pick up some zip ties and i made sure I drove it a little hard to test out my set-up and when I got home I checked and everything was still in place, so hopefully it will stay that way.

I have to drive to Glendale to work tommorow so that will be the real test.....10 minutes of highway driving.

I also coulnt get the damn breather tube to stay in its grommet, so i rigged up this little ghetto zip tie restraint for it, but now it doesnt really go in the grommet very far. How far in does the breather thing need to be in to function? I'm thinking about abandoning the zip tie idea and just sealing it in there with silicon
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Old 02-26-2005, 07:59 PM   #9
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i have an ebay cai and i had the same problem, just seemed like it didnt wanna fit quite right, but ive had it for months and have no problems at all, u should be fine
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Old 02-26-2005, 09:39 PM   #10
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They say that spending $100+ on an intake is worthless because the $50 ebay intakes do the same thing...

That may be true to a certain extent. To that I say match up car for car and then time the installation for the ebay CAI and lets say a Densecharger from Demolet. Guarenteed you will get the Densecharger in faster than the Ebay CAI. You know why? You get what you pay for. For that little extra cash you can get a CAI that fits perfectly and would not move a millimeter even if a bomb went off.

I'm not dissing your purchase in anyway. I was going to buy an ebay CAI also, but I got a good deal from Demolet so I got it instead. This is merely a post for those who may purchase a CAI in the future.
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Old 02-26-2005, 10:03 PM   #11
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Quote:
Originally Posted by NJStang86
They say that spending $100+ on an intake is worthless because the $50 ebay intakes do the same thing...

That may be true to a certain extent. To that I say match up car for car and then time the installation for the ebay CAI and lets say a Densecharger from Demolet. Guarenteed you will get the Densecharger in faster than the Ebay CAI. You know why? You get what you pay for. For that little extra cash you can get a CAI that fits perfectly and would not move a millimeter even if a bomb went off.

I'm not dissing your purchase in anyway. I was going to buy an ebay CAI also, but I got a good deal from Demolet so I got it instead. This is merely a post for those who may purchase a CAI in the future.
I was going to get a Densecharger, but he doesn't make a full-length for the '95, only '99+.
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Old 02-26-2005, 10:14 PM   #12
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What I've seen some installs do is WHACK the strut-tower to make room for the CAI tube. I have also seen pix of CAI pipes that people have curb-whacked to make them fit against the strut tower, but it defeats the whole purpose of the tubing, and the benefits of the CAI are compromised.
I think the problem here is the short-sightedness of the "engineers" that make these. If the pipe "fits" 30 different applications, they make you do the final fit, which as you can see is often lacking.
There is a way to fix this, the first involves a welder and a hacksaw, and the second, your original throttle body air intake neck(the last 4"). If you have the original air intake hose laying around, cut off 4"(measured on the inside radius, about 8" outside) at the throttle body end, and insert your CAI tube into it, and the other end to the TB. It will take some work, as your CAI tube will be a tight fit, but once you're done, you will have a better fit, and less wory.
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Old 02-26-2005, 10:30 PM   #13
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Quote:
Originally Posted by CakeOrDeath?
I was going to get a Densecharger, but he doesn't make a full-length for the '95, only '99+.
That's right...my mistake. I remember he had them for a limited time or was supposed to make them, but there just wasn't enough interest or something along those lines. I'm sure if you got a bunch of pre-99 3.8 owners together, he might fab something up. Anythings possible.

Good luck with making your intake fit. You'll love it when it's done
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Old 02-27-2005, 09:02 AM   #14
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A Demolet full-length conversion sounds like a good project!
This stuff is really pretty easy, we need a how-to for the board.
I built some CAI stuff, (PVC pipe) that works well, but near the
engine it can get deformed by heat. 1 I did for my 4cyl Vert warped
at the TB where the clamp was, reduced the ID a bit. I also noted
that Demolet uses really thick plastic near the engine.


Glad I could Help C/or/D!
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Old 02-27-2005, 09:23 AM   #15
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Demolet uses ABS " plastic pipe
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