New Cold Air Intake

CoastieSCPO · 03-30-2010, 03:43 PM

Well, I just have to tell you all about the install of my new CAI purchased from Brazels. First, this is not an indictment of the nice folks at Brazels, rather just a blow by blow of the problems, and solutions that I experienced when installing the new CAI.

Man, was I excited to get it as we've been really looking forward to start the upgrades that I have planned for my coach. Removing the stock air system seemed to be straight forward and easy and was for 90 % of the work. Until we started removing the air box from the brackets holding it to the frame. The instructions say that the are four bolts to remove. Well, my MH had two bolts and two empty spaces where bolts could have and should have gone. Not so with this Workhorse. It (the bracket) was welded to the frame, on the top of the old air box. The air box had to be almost totally disassembled just to make room to use the Dremel tool brake the weld (3 inched long). What a pain in the butt. No fault of Brazels! Just a lazy worker who assembled my MH.

Big problems with the install of the new CAI. First, the 3 inch connector that is provided to connect the MAF with the new high efficiency tube is 4 inches in diameter. The problem is that the MAF is 3.75 inches and everything forward of it is 4 inches. It don't fit correctly! Now, the new tube can be tightened down to nearly fit, which is what I did, but that is not a correct fit, IMHO. Next, the new air box fit above the frame, next to the battery, alongside of all the tubes wires and radiator container. But, I cannot access the filter inside from the grill due to all the "stuff"in the way. The box is too big! This is the fault of either Tiffin or Workhorse, not Brazels.

So, we got it installed. But I will still have to access the box from the wheel well, remove the entire box, just to clean the new fancy filter. What a Pain. At least there will be no more water intrusion into the filter, like the stock system (I hope). Also, I've ordered a 4"to 3.75" reducer from one of the performance dealers available. You know, I seriously considered the DIY route, using a battery box from Wallyword, like my friend Oemy, but didn't. Live and learn!

In closing, this is not a critique of anyone, rather just an effort to tell what I just experienced. In fact, when the time is right, I will be purchasing a new Ultra Power from Brazels, and man, that 8.1 is going to growl like a lion.

Bob

oemtech · 03-30-2010, 07:38 PM

This is not an uncommon problem when you try to design and build a product that is based on the information retrieved from prototype installs. I have done a number of then and had to fab up mounting brackets, move OEM brackets, cut welds etc.

**"007"** · 03-30-2010, 10:15 PM

Any time you add something in that area you will have some work to do I had to cut a 1" square D frame the height of box, to fit in the box, had no problem fitting to sensor tube.
Once done sure cleaned up area.

DriVer · 03-31-2010, 07:52 AM

Mine bolted right on top of the rail bumper no problem. On other coaches I have had to install a major spacer to clear the hydraulic hoses that came around the radiator mount.

When I need to remove mine I have to remove 2 bolts inside the unit that hold it on the bumper and unscrew the clamps. I did not need any reducers or other plumbing modifications.

Ultrapower Cold Air Intake. Note the big bungee cord in the wheel well, it just provides enough support to take the load off of the back of the unit when hitting rough stretches of road.

CoastieSCPO · 03-31-2010, 07:59 AM

Thanks guys for your responses. I have my box temporarily screwed into the bottom of the box up thru some very nicely spaced holes that were already in the frame. I'm going to try to move some stuff around to facilitate better access, but it is very tight.

Question: I'm going to take the rig out for a run. What is a proper reading on my Scan Gauge for the MAF now that the Ultra CAI is installed?

JonBrazel · 03-31-2010, 10:35 AM

More important is to program in fuel trims and see what kind of numbers you get. Optimum is as close to 0 as possible but + - 10% is acceptable.

CoastieSCPO · 03-31-2010, 11:31 AM

Thanks Jon!

DriVer · 03-31-2010, 01:13 PM

Quote:

Originally Posted by JonBrazel

....

U Da Man!

CoastieSCPO · 03-31-2010, 02:11 PM

I took the MH for a nice afternoon drive and just finished washing it and put it to bed. Everything worked well. I took it up to speed a couple of times and you can certainly hear the Ultra CAI growl. Nothing too bad though, but didn't have the wife with me. Just the dog. He could care less; just wanted to go for a ride.

I ran thru some of the Scan Gauge readings and they all looked OK to my uneducated eyes. Not too certain what I'm looking for insofar as reading the fuel trims as Jon suggested. I'm checking the manual to learn more. Tomorrow, we'll try to make more room for the new air box. I'll take some photos.

Bob