Loose CAI

mechanic69 · May 29, 2015

Ive had a kind of hollow knocking noise for the last couple of weeks, couldn't pin point it and only noticeable with the radio off. Thought it was something to do with my uprated ARB and drop links. But when I checked the engine bay today found the bolt holding the CIA to the head had come undone and the CAI was loose and rattling about!

Anyone any tips to keeping the ****** in or do you check it regularly? Too scared to tighten it too much incase I strip the thread.

illogik · May 29, 2015

Hmm...I'd say get a new crush washer and Loctite the screw.

mechanic69 · May 29, 2015

if I loctite it can i get it out after?

niallh · May 30, 2015

mechanic69 said:
if I loctite it can i get it out after?

Iv loctite'd mine and ive taken it off a few times since then

mechanic69 · May 30, 2015

Cheers, seen someone on here fitted a second clamp on the corner over the exhaust but I can't see where to fit it to the engine.

s3_trev · May 30, 2015

This is a shortcoming in the design of the revo intake in my humble opinion. I had the exact same issue with mine. So in addition to the little screw that you have an arrow pointing to, I have now reinforced my intake both at the top (clamp round the pipe just before the MAF) and at the bottom (bolted the heat shield down). Now its the way it SHOULD have been. Acceptable in other words. Wouldnt hold your breath on that PCV delete either but that's another story.

s3_trev · May 30, 2015

There is no way that one wee screw is enough to support that entire intake pipe, especially if your car has stiffer/lower suspension, its a given that its going to come loose and cause issues. Hence my upgrades. See below.

You will notice that I also trimmed back a bit more of the heat shield at the bottom to prevent the two clamps from grinding on it, as well as replacing the totally wick looking rubber beading that came around the edge of the heat shield, with something tidier looking. I have more detailed pics if you are interested I will post them.

nooone · May 31, 2015

Intake weighs very little. As the bolt is isolating from the intake via a rubber section, don't over tighten (you'll just put more pressure on the rubber).

Replace the nut with a nylock.

mechanic69 · May 31, 2015

Cheers tree any pics of your clamping arrangement?

Not sure about the pcv what do you say about it?

s3_trev · May 31, 2015

No problem. Closer pic of the top support bracket. Hole I used wasnt being used anymore due to the TTS cover hence free to use for this:

Closer pic of how I mounted the heat shield to the car (everything was painted black after this):

Image showing how the totally stock setup causes the clamps to grind against the heat shield. If this happens while you are driving you would think your engine is about to fall apart!! Again, this is amplified if your car suspension has been lowered / hardened. I trimmed this back a bit to fix the problem.

Finished product with the TTS cover. You will notice the rubber edging has lifted off slightly on the heat shield. This was fixed immediately after this pic was taken, with some glue:

I can report I have had no issues with the kit now, having done 10-15k since I done the above.

s3_trev · May 31, 2015

Regarding the PCV delete. I do not think I can really put any blame on revo for this as all PCV deletes are basically carbon copies of each other. But see below pics and you can come to your own conclusions of what the issue was. Bearing in mind this was fitted by a fully qualified mechanic and a guy that isn't stupid.

Below pic shows that my cam cover isnt flush with the square. Did the PCV delete do this? I dont know, as I didnt do this test before the delete kit went on. But its like that now.

So all I could do was either buy a new cam cover, or do what I did - which was get a new seal (the orange bit) and put the OEM pcv system back on. Due to it being plastic it makes a better seal with the plastic cam cover. I cant say Ive had any issues since. But id never use a PCV delete kit again.

mechanic69 · Jun 1, 2015

s3_trev said:
No problem. Closer pic of the top support bracket. Hole I used wasnt being used anymore due to the TTS cover hence free to use for this:

Closer pic of how I mounted the heat shield to the car (everything was painted black after this):

Image showing how the totally stock setup causes the clamps to grind against the heat shield. If this happens while you are driving you would think your engine is about to fall apart!! Again, this is amplified if your car suspension has been lowered / hardened. I trimmed this back a bit to fix the problem.

Finished product with the TTS cover. You will notice the rubber edging has lifted off slightly on the heat shield. This was fixed immediately after this pic was taken, with some glue:

I can report I have had no issues with the kit now, having done 10-15k since I done the above.

Thanks for that I'll see if I have similar mounting point

mechanic69 · Jun 1, 2015

s3_trev said:
Regarding the PCV delete. I do not think I can really put any blame on revo for this as all PCV deletes are basically carbon copies of each other. But see below pics and you can come to your own conclusions of what the issue was. Bearing in mind this was fitted by a fully qualified mechanic and a guy that isn't stupid.

Below pic shows that my cam cover isnt flush with the square. Did the PCV delete do this? I dont know, as I didnt do this test before the delete kit went on. But its like that now.

So all I could do was either buy a new cam cover, or do what I did - which was get a new seal (the orange bit) and put the OEM pcv system back on. Due to it being plastic it makes a better seal with the plastic cam cover. I cant say Ive had any issues since. But id never use a PCV delete kit again.

I don't seem to have that problem yet but might check again. I am getting evap code coming up tho?

s3_trev · Jun 3, 2015

You should have an identical mounting point mate. Not sure about the evap code sorry.

XFi · Jun 7, 2015

With regards to the PCV delete I had an issue with mine where it was bringing an error code up saying it was too rich at idle. After a few garages took a look and also the mappers confirming it isn't there map I discovered it was the PCV delete. Since a new gasket it hasn't returned and that was probably 8 months ago now.

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Loose CAI

mechanic69

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illogik

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mechanic69

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niallh

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mechanic69

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s3_trev

Northern Ireland

s3_trev

Northern Ireland

nooone

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mechanic69

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s3_trev

Northern Ireland

s3_trev

Northern Ireland

mechanic69

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mechanic69

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s3_trev

Northern Ireland

XFi

In need of a V8.

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