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Induction Kit

Discussion in 'Modifications' started by Klausanta, Apr 23, 2013.

  1. Klausanta

    Klausanta Copenworld Member

    Joined:
    Sep 27, 2012
    Location:
    Surrey
    Car(s):
    Renault Megane
    Hi

    I am still waiting for the parts to arrive from eBay to sort the old induction kit out on our Copen but while waiting I happened across Adam K’s pictures showing his very impressive setup.

    https://www.copenworld.com/vb3/showthread.php?t=561&page=4

    I’m afraid in comparison mine was manufactured by ‘Heath Robinson’ in conjunction with ‘Marley Plumbing’. The components used in my version are shown below and as far as I can see all the original air box components had been removed and a simple metal straight pipe join fitted to the original air hose (1). A rubber hose (maybe the original) was then modified/fitted (2) and connected to a mushroom filter (3) via a 90 degree Marley gutter bend (4) and finally this was all held in place with just a small white cable tie (5).

    I have ordered a number of relatively low cost components that should provide a much better solution and will add some details/pictures when everything arrives and is fitted. In the meantime, I have a couple of questions that I hope someone or/and Adam K can answer for me.

    1. In the pictures from Adam K there is a hole in the top of the cone filter for what I believe (and is shown fitted) the ‘air flow’ sensor. I could not see this sensor anywhere on our old induction kit and there is no hole in the cone filter I have ordered. Any suggestions or comment on where the sensor may be located or if it is actually needed?

    2. Are there any clear instructions on how to (easily) remove the front bumper anywhere please?

    Many thanks

    KS
     

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  2. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
    Location:
    Worcester, UK
    Car(s):
    Nissan Cube Kaizen
    That is a bit of half arsed job. Everything after the flexible hose coming through the front bulkhead isn't standard. In your first picture in the top right is the cable for the sensor. I guess it's just dangling down behind the bumper.
    Taking the bumper if simple enough. I'll try to find a how to for you.
     
  3. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
    Location:
    Worcester, UK
    Car(s):
    Nissan Cube Kaizen
    See section I2-1of the service manual for removal of the bumper.
     
  4. trustafox

    trustafox Copenworld Guru

    Joined:
    Nov 19, 2012
    Location:
    East Mids
    Car(s):
    Yes
    Wow your car must have moved like a rat up a drain pipe!!

    Is that a temperature sensor Adam?
     
  5. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
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    Worcester, UK
    Car(s):
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    Yep, it's the Intake Air Temperature sensor.
     
  6. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
    Location:
    Worcester, UK
    Car(s):
    Nissan Cube Kaizen
    I've been looking more at your set-up.
    For the mushroom type foam filter used. The position of the filter is not good. The filter is absolutely filthy. I think you'll notice a difference when you put a new filter in.
    It would get very wet whilst driving in the rain, from water passing through the grill. Unless there is a cover behind the grill that you haven't shown (like the one on my set-up).
    When you tidy things up you should try to match the HKS kit.
    http://www.hks-power.co.jp/en/product_db/intake/db/5590

    The mushroom filter is placed high up & has a shield to protect it from moisture.
     
  7. Klausanta

    Klausanta Copenworld Member

    Joined:
    Sep 27, 2012
    Location:
    Surrey
    Car(s):
    Renault Megane
    Hi Adam

    I am not going with a mushroom filter again as I am going to use a cone filter like yours. However, I completely neglected to think about a protective cover.

    I can't see where your cover is actually fitted but is it just to stop water hitting the filter and does this cover not reduce the air flow?

    What does the air temperature sensor do? If mine is not fitted will it cause a problem as it does not seem to make any difference at the moment?

    Many thanks for all your help and guidance

    KS
     
  8. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
    Location:
    Worcester, UK
    Car(s):
    Nissan Cube Kaizen
    My Cone filter is a stainless mesh that does not require cleaning. I am yet to see a similar type here in the UK. Cone filter's here seem to be the K&N style where an oil is loaded to the filter. Which needs to be cleaned periodically.
    It's not good to get these types wet either.

    The cover just protects the filter from direct weather & debris. The standard air filter housing took air in from behind the bumper & wing. So that source of airflow is unaffected.

    Take a look at the Technical Information manual (available to download from the directory tab). Section B03 shows a nice picture of the standard filter set up showing the airflow actual enters from the rear not the front.

    You could use one of these Heat shield as your guard.
    http://www.ebay.co.uk/itm/UNIVERSAL...arts_Vehicles_CarParts_SM&hash=item3f246b170b

    This is the Take Off, Super Genki Kun induction Kit for the Copen.
    http://www.k-takeoff.com/catalog/other/image/sgenki_l880-l.jpg
    You can see the heat shield type cover shown.

    I'm not fully versed in how the sensor works, but I guess it helps the ECU control the amount of fuel dependent on air temperature mix. With the sensor dangling in the area where the air is coming into the filter, I doubt the measured signal would be that different from it being inside the intake itself.

    It's not an easy job to try & make your own induction kit. Which is why I just bought one. More expensive but easier.
     
  9. Lotuseater

    Lotuseater Copenworld Regular

    Joined:
    Dec 13, 2010
    Car(s):
    1.3 Copen
    Wow! the first thing that comes to my mind is fire hazard? I'm not sure that a piece of plastic drain pipe is going to be fire resistant! That said I'm sure that your replacement parts from ebay will meet all requirements!

    Good luck and I look forward to seeing how you get along.

    Regards..
     
  10. Klausanta

    Klausanta Copenworld Member

    Joined:
    Sep 27, 2012
    Location:
    Surrey
    Car(s):
    Renault Megane
    Hi All

    I have now got most of the parts I need to modify my set up (apart from the cone filter cover) and I have now had an opportunity to look for the missing 'air temperature sensor'.

    Comparing the wires on Adam K's picture and mine, I think that I have found the sensor and to this there is some sort of blanking plate pushed into the connector (unless this is the sensor) which then seems to fit perfectly into the rubber grommet/bracket that previously may have located a fixing for the original air box assembly?

    If this is correct, the air temperature sensor has been disabled, or I think in this case removed completely?

    I was going to cut a hole in the hosing of the new set up to accommodate the sensor but this would now appear to be pointless?

    KS
     

    Attached Files:

  11. trustafox

    trustafox Copenworld Guru

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    That temp sensor is not blanked off, its the same as mine even on the 1.3 big boy.
     
  12. trustafox

    trustafox Copenworld Guru

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    Adam is probably correct and what I would have said, that the ECU takes the incoming air temp and uses an algorithm to calculate the amount of fuel required for the amount of oxygen available. Air is about 10% different in density from a cold day at 5°C to a warm day at 30°C (OK a hot day for the UK).

    Hence more fuel is thrown in when its cold and you get more horses. If if didn't on cold days you'd be running lean and potentially over heat the plugs. On hot day you could run rich and foul the plugs. I'm guessing the O2 sensor helps prevent this also.
     
  13. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
    Location:
    Worcester, UK
    Car(s):
    Nissan Cube Kaizen
    Yep, that's the sensor alright. I like the way they fitted it into the old mounting. At least they didn't just leave it hanging. I don't think it's been disabled.

    Yes, when you make your kit you should make a hole in the hose to fit it into.
     
  14. Klausanta

    Klausanta Copenworld Member

    Joined:
    Sep 27, 2012
    Location:
    Surrey
    Car(s):
    Renault Megane
    I fitted the induction kit parts yesterday and everything went in very well.

    I used a ‘Pipercross Alloy Neck Cone Filter’ which is extremely light and has a 56mm diameter neck.

    http://www.ebay.co.uk/itm/PiperCros...arts_Vehicles_CarParts_SM&hash=item5637aa3e33

    I then used a ‘90 Degree Reducer Silicone Elbow Bend Hose’ to connect the filter to the system. This reduced the hose size from 57mm at the filter end to 51mm at the engine end and both connections were then held in place with standard adjustable Jubilee clips.

    http://www.ebay.co.uk/itm/270865046...eName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

    Although it was a tight fit, I did not need to remove the front bumper just the front grille and two of the front bumper retaining bolts but the hose needed to be cut to fit at the engine end to get the correct alignment.

    I was going to use a ‘Universal Exhaust Bracket’ to hold everything in place and this would have fitted around the filter neck and been fixed on the spare hole to the right of the filter as per Adam K’s system, but everything fitted so well (and rested on the old air box mounts) that I did not bother in the end.

    http://www.ebay.co.uk/itm/280964832301?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

    The filter is a little exposed to water from the grille but I have not yet decided if I am going to fit some form of cover. I also left the air temperature sensor as it was as due to the length of the black part on the end as it would not have fitted where I intended to drill a hole and locate it in the hose. More thought is required on these two aspects I think.

    KS
     

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  15. Adam K

    Adam K Copenworld Guru

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    Looking good. Did you notice any difference?
     
  16. Klausanta

    Klausanta Copenworld Member

    Joined:
    Sep 27, 2012
    Location:
    Surrey
    Car(s):
    Renault Megane
    To be honest Adam, no I can’t say I notice any difference.

    I thought it would change the engine noise but it sounds about the same as before but at least I know it is now fitted correctly.

    KS
     
  17. trustafox

    trustafox Copenworld Guru

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    Location:
    East Mids
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    Could you not drill a hole in the cone section of the aluminium neck? The sensor then should protrude into the middle of the inside filter space and use a rubber grommet

    http://www.ebay.co.uk/itm/RUBBER-GROMMETS-6-9-12-16-20-25-32-38-50mm-1-4-3-8-1-2-5-8-1-2-cable-/281026511967?pt=UK_DIY_Material_Electrical_Fittings_MJ&var=&hash=item416e7c445f

    As your system was already modified and what you had got used to, I'm not surprised you don't notice any difference. May be if you had gone from stock you would have.
    Looks good though.
     
  18. Tassie Devil

    Tassie Devil Copenworld Newbie

    Joined:
    Nov 21, 2018
    Location:
    Tasmania
    Car(s):
    2003 Diahatsu Copen 0.7 turbo
    What other mods were done before the new induction ??
     

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