Free PDF Manual Guide

VAUXHALL / OPEL 57-0005 Instruction sheet A2054-41-3 CAVALIER / ASCONA 1982-88 Astra / Kadett -1986 Page 1 of 3 PLEASE READ THE INSTRUCTIONS CAREFULLY BEFORE FITTING THE KIT. If you have a problem, however small, call our Technical Department. Tel:- 01925 636950. Fax:- 01925 243111. Mon to Thurs 8.30 – 5pm. 1 Remove the plug from the Air Flow Meter (AFM). Release the hose on the intake pipe and remove the air box lid. Release the three remaining air box retaining screws and remove the air box base. 2 Remove the AFM from the air box lid and fit the new adaptor and gasket to the AFM with the four countersunk screws supplied. 3 Fit the mounting bracket to the AFM with the two screws supplied. 4. Cut out and position the template, tape in place, centre punch the two points and drill two holes 8.5mm diameter. Finally fit the
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Tools Required:
Phillips Screwdriver
Screwdriver
8mm Nut driver
10mm wrench

Parts Included:
EVO High Flow Cotton Air Filter X1
EVO Plastic 6” Venturi X1
EVO Billet Aluminum Venturi Tube X1
EVO Heat shield w/ Spring
Clamp Installed X1
EVO Heat shield cover w/
Stainless V-Flow Tag X1
Hose clamps X2
10mm Bolts X3
Small washers X3
Breather Filter X1
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Read and understand these instructions BEFORE attempting to install this product.
1) Getting started
a) Make sure vehicle is parked on a level surface.
b) Set parking brake.
c) Make sure you have the anti-theft code for the radio.
d) Disconnect negative battery terminal.
e) If engine has run within the past two hours let it cool down.
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Congratulations! You have just purchased the best engineered, dyno-prove intake system available. Please check the contents of this box immediately. Report any defective or missing parts to the Authorized Injen Technology dealer you purchased this product from. Before installing any parts of this system, please read the instructions thoroughly. If you have any questions regarding installation please contact the dealer you purchased this product from. Installation DOES require some mechanical skills. A qualified mechanic is always recommended. *Do not attempt to install the intake system while the engine is hot. The installation may require removal of radiator fluid line that may be hot. Injen Technology offers a limited lifetime warranty to the original purchaser against defects in materials and workmanship. Warranty claims must be handled through the dealer from which the item was purchased.
Note: Disconnect the negative battery teriminal before starting this installation.
1 Remove the air intake box cover and intake air intake duct leading to the throttle body.
2 Remove the PCV pipe as seen in figure 4 and replace the water bypass valve with the 15”- 6mm hose provided in the kit. The coolant line port is located on the intake manifold housing . See diagram’s A or B The location of the coolant line port hose may vary depending on the year of your car. ( Do not attempt to remove any lines until your engine is cool to the touch.)
3 All Ex-models 94-97- Remove all of the components as seen in diagram C- #8. Since the cold air intake is not being used in this application the air resonator box can remain in the stock location. Once the components have been removed from the metal pipe leading to the EGR valve, you may cap-off or plug as indicated in figure 6 and diagram C. Use the 5mm vacuum cap to seal the line.
4 Screw the vibra-mount into the fender wall as seen in figure 3 and use the m6 nut and washer to attach it.
5 Place the step hose onto the throttle body and use two clamps and tighten the clamp on the throttler body at this point. See fig. 2
6 Place the end of the intake with the 1/2” aluminum nipple into the 3” side of the step hose and align the bracket on the intake to the vibra-mount stud and semi-tighten the nut and clamp. See figs. 5 and 7

Source

Removal
1. Relieve the fuel pressure in the system by loosening the banjo bolt on the top of the fuel filter. Disconnect the fuel line from the fuel rail. It is a good idea to replace the washers. Disconnect the fuel harness holder and unbolt. Disconnect the hoses from the fuel pressure regulator (FPR).
2. Disconnect intake hose/pipe from throttle body. Disconnect all hoses leading to the throttle body and intake manifold. Disconnect throttle cable bracket on manifold and throttle cable from throttle body. Disconnect the cables to the the throttle position sensor (TPS) and the map sensor on the throttle body.
3. Unbolt two lower intake manifold bolts that secure manifold to engine block. This bracket willl still be used to accommodate the heater bypass pipe. Unbolt manifold from engine block. Remove manifold, throttle body, and fuel rail as one unit.
4. Remove the intake air bypass (IAB) vacuum tank, check valve and control solenoid unit. Due to the different design of your new manifold, these parts will no longer be used. Do not remove the FPR hose. This hose will be used in the re-installation process.
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1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable.
2. Disconnect the air temperature sensor electrical connection as shown.
3. Unclip the battery cable from the air inlet duct as shown.
4. Loosen and remove the two bolts that secure the air inlet duct as shown.
5. Remove the air inlet duct.
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Shopping list from FORD dealer, $15.00 for 2 sets of heater hose o-rings and snap clips, $40.00 heater core, (cheaper at the dealer but no warrantee, aftermarket parts store model preferred by many @ $55) insulated foam tape to wrap new core with (parts dept just gave me what I needed), and a gallon of anti freeze.
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The Motorola HCS12 family of micro-controllers was designed primarily for operation in Single-Chip mode. In Single-Chip mode all the peripherals are found either internally in the HCS12 silicon, or can be connected to the HCS12 through one of its serial interfaces like the SPI, SCI or IIC. In practice over 95% of HCS12 based designs use Single-Chip mode.
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The K&Nо Drycharger included with this kit must be installed on the K&Nо air filter when used with this K&Nо cold air intake system. The K&N cold air intake system a performance product that can be used safely during mild weather conditions. During harsh and inclement weather conditions, you must convert your cold air intake system to a short ram configuration, or return your vehicle to the stock OEM air box and intake tract configuration. Failure to follow these instructions can void your warranty.
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Before you start installation
Take some engine bay pictures for later reference.
Make a special drawing of all the coolant hoses going to the different parts of the stock intake, you will need this later on. The same goes for the vacuum hoses to the different parts of the intake.
Mark the electrical connectors to the MAP sensor and TPS sensor. You will need this later on.
Drain the engine coolant.
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