Rotary Extreme - RX-8 Intake Installation

Rotary Extreme RX-8 Short Arm Intake Installation:

Thank you for purchasing the Rotary Extreme Short Arm RX-8 Intake. Please follow the instruction closely. Improper installation will affect the performance of the intake kit and will cause rough idle or possible hesitation.

Tools:

Metric Socket Wrench Set with 10mm and 11mm sockets.
Flat Head Screw Driver.
Philips Screw Driver
11mm Wrench
9/64 Allen wrench

Installation:

1.Turn the engine off with the key at the "off" position. DO NOT install the intake with the ignition key on or engine running. Doing so will make the check engine light come on.
2. Disconnect the air flow sensor connector and the fresh air duct solenoid valve connector. The solenoid valve is the one that's bolted onto the air box. Remove the vacuum hoses attached to the solenoid valve. Remove the wiring retainer from the air box.
3. Loosen the clamp that secures the accordian tube onto the air box. Push the accordian tube back and slide the air box out by lifting it up.
4. Unbolt the air flow sensor using a Philips screw driver. Make sure you handle the sensor with care. DO NOT touch the wire on the air flow sensor.
4. Unbolt the solenoid valve from the air box using a 10mm socket. If you have an automatic RX8, there is no solenoid valve. Ignore the instructions that involve the solenoid valve.
5. Bolt the air flow sensor onto the intake tube using the Allen screws provided and 9/64 Allen wrench.
6. Using masking tape to make a 2" mark from the bottom of the intake tube. When you clamp on the filter, make sure the top edge of the filter flange meets the mark. Do not bolt on the air filter yet.
7. Slide the intake pipe through the center hole on the heat shield. Bolt the solenoid valve onto the heat shield at the same time.
8. Leave the metal tube on top of the radiator shield open to the atmosphere.
9. Take one section of the vacuum hose you take off and connect it to the 90 degree white nipple located at the front of rectangular chamber at the accordian tube.
10. Bolt on the heat shield using the stock bolts. Please make sure you put on the heat shield with the right orientation. The top 90 degree bend goes toward the back of the car. If you put on the heat shield inside out, it will misalign with the top cover. You might want to remove the battery cover so it's easier to slide the heat shield in place. Connect the tube coming from the 90 degree nipple to the top metal nipple of the solenoid valve. Leave the black nipple on the solenoid valve unconnected. Connect the solenoid valve connector and also the air flow sensor connector. Clamp the accordian tube onto the intake pipe using the stainless steel clamp provided. DO NOT use the stock clamp. The accordian tube has to be clamped onto the intake pipe tightly without leakage. Any leakage will cause rough idle. Make sure the MAF is at the upright position as shown in the photo. DO NOT rotate the pipe in any other position.
11. Bolt on the filter to the intake pipe to the mark. Tighten the clamp fully. Make sure there is no oil or grease on the filter and the intake pipe or the filter might slip off. If there is oil or grease, spray some brake cleaner or rubbing alcohol on a rag and wipe them clean. DO NOT spray brake cleaner directly onto the filter.
12. Bolt on the 2" screws onto the top cover using a 11mm wrench and a Philips screw driver.
13. Slide the screws into the existing holes.
14. Bolt on the top cover using the provided bolts and nuts using the 11mm wrench and 11mm socket wrench
14. Before you bolt on the engine top cover, make sure the connectors for the air flow sensor and solenoid valves are connected securely. Put on the engine top cover. Installation is complete.