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The Mazda RX-7 FD is renowned for its lightweight design and exceptional handling, but many enthusiasts seek to enhance its performance further. One popular modification is the installation of a custom intake system, which can yield significant horsepower gains. This article will guide you through the process of installing a custom intake system on your FD RX-7, aiming for 20+ horsepower increases.
Understanding the Benefits of a Custom Intake System
A custom intake system can provide several advantages over the factory setup. Here are some key benefits:
- Increased Airflow: A custom intake allows for better airflow to the engine, which can improve combustion efficiency.
- Enhanced Sound: Many enthusiasts enjoy the deeper, more aggressive sound that an aftermarket intake can provide.
- Weight Reduction: Custom intakes can be lighter than stock components, contributing to overall weight savings.
- Improved Throttle Response: A more efficient intake system can lead to quicker throttle response and acceleration.
Tools and Materials Needed
Before starting the installation process, gather the necessary tools and materials:
- Socket set
- Ratchet and extensions
- Flathead and Phillips screwdrivers
- Torque wrench
- Custom intake system kit
- Air filter (if not included in the kit)
- Heat-resistant silicone couplers
- Zip ties
Step-by-Step Installation Process
Step 1: Preparation
Begin by ensuring your vehicle is parked on a flat surface and the engine is cool. Disconnect the battery to prevent any electrical issues during installation. Remove any components obstructing access to the factory intake system, such as the engine cover.
Step 2: Remove the Factory Intake
Using your socket set, remove the bolts securing the factory airbox. Carefully disconnect the intake duct and any sensors connected to the factory intake. Set these components aside for potential reuse or disposal.
Step 3: Install the Custom Intake
Follow the instructions included with your custom intake system. Begin by fitting the new intake pipe into the engine bay, ensuring it aligns with the throttle body. Use heat-resistant silicone couplers to secure connections as needed.
Step 4: Attach the Air Filter
Attach the air filter to the end of the intake pipe. Ensure it is secured tightly to prevent any unfiltered air from entering the engine. If your kit includes a heat shield, install it according to the manufacturer’s instructions.
Step 5: Reconnect Sensors and Components
Reconnect any sensors or components that were removed during the disassembly. Double-check all connections to ensure they are secure and properly seated. Use zip ties to tidy up any loose wiring or hoses.
Step 6: Final Checks
Before closing the hood, perform a final inspection of the installation. Ensure all bolts are tightened to the manufacturer’s specifications using a torque wrench. Reconnect the battery and start the engine to check for any unusual sounds or leaks.
Tuning Your RX-7 for Maximum Gains
After installing the custom intake system, consider tuning your RX-7 to maximize the performance gains. Here are some tuning options:
- ECU Remapping: Reprogramming the ECU can optimize fuel maps for the new airflow characteristics.
- Upgraded Exhaust System: Pairing your intake with a high-performance exhaust can further enhance horsepower and torque.
- Dyno Tuning: Visiting a professional tuner can help you achieve the best results specific to your vehicle’s setup.
Conclusion
Installing a custom intake system on your FD RX-7 can be a rewarding project that enhances both performance and driving experience. With careful preparation and attention to detail, you can achieve the desired horsepower gains and enjoy the improved responsiveness of your vehicle. Always remember to follow up with proper tuning to fully realize the benefits of your new intake system.