Balancing Act

DIY: Injen cold air intake installation guide for 2002-2006 Acura RSX Type-S manual 6-speed

Small update for June. Here is a comprehensive guide I've written back in January 2009 on how to install an Injen cold air intake system onto your 2002-2006 Acura RSX Type-S 6-speed. Allow approximately 2-3 hours to complete this project.

Injen cold air intake parts check list

1 Injen Cold Air Intake system
1 2-7/8” x 3” 60 degree elbow
2 m6xm25 bolts (for reservoir tank)
2 fender washers (for reservoir tank)
1 1525 sensor grommet
1 20” - 8mm vacuum hose and 1 18” - 17mm vacuum hose
1 3” Injen filter
1 custom roto-molded windshield reservoir tank

I.Installing the cold air intake system

Disconnecting the battery (optional step)

Set your transmission to 5th gear before you start. Removing the battery is an optional step. The purpose of this step is to remove the protruding metal bracket from the battery bay for clearance. You can alternatively just bend the bracket downward. Omitting this step will save you approximately 20-30 minutes.

Disconnect and remove the battery. You’ll need to modify a piece of the battery holder to clear room for installing the intake later. Remember to have your stereo security code ready! Once you remove the battery, drill off the extended bracket that is securing two power sockets in place. To remove the socket, locate a pinch clip on each, press down and then slide it out of the bracket. Using a drill and a 4/16 bit, drill off the 2 soft spot welds:

When you’ve completely drilled through the soft spot welds, bend the protruding metal bracket up and down a couple of times to dislodge it:

II.Remove your front bumper and stock air box

Remove all the vacuum hoses attached to the stock air box. You need pinch clamp clips to release the hoses, which can be difficult. If you have a hard time holding the clips down, use a pair of pliers. Essentially, remove the main large hose from the brake booster port, and then remove the smaller hose from the crank case port. Finally, remove the air temperature sensor and set it aside. You are disconnecting 2 hoses and 1 sensor from the main stock air box setup.

Next, remove the main air box. Untighten the clamp on the air tube connecting from the air box to the throttle body and then remove the air tube. Remove the air box by unbolting five 10mm bolts. Four of these bolts are easily accessible, the 5th one you will need to remove a rubber grommet to access:

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With all five bolts removed, carefully lift the air box up and maneuver it out of its bay; dislodging it from the stock air inlet tube. Next, remove the stock air inlet tube by unbolting a 10mm bolt located on the radiator frame.

The stock box removed:

The engine bay without the stock air box.

III.Replace windshield wiper fluid reservoir

With the bumper removed, you have full access to the stock reservoir. Unplug the two power plugs (yellow and blue plugs) from the motors:

Remove the reservoir filler cap by unclipping it from its holder and then pulling it upward with slight force:

Remove the three 10mm bolts securing the stock reservoir in place, then guide the entire reservoir down until the fill-tube is completely visible:

With the entire reservoir removed, you may want to empty the reservoir of its content at this time. Separate the filler tube from the reservoir tank by pulling it out of its rubber grommet. Remove the rubber grommet.

Next remove the two motors by pulling them downward, then remove the two black grommets:

Next, transfer the rubber grommets to the Injen replacement reservoir tank:

Cut a hole about 4”x5” on the wheel well splash guard and the engine guard. You need to make two incision so you can install the intake. The trick is to start with a small hole and increase gradually until you made the correct size:

Continue cutting.
The completed hole.
It took me a total of 5 minutes to make the holes using garden pruners.

After cutting the holes on the splash guards, reattach the motors and the filler tube:

Position the Injen reservoir tank for installation, then install the vibra-mount (without the washer and flange nut) onto the upper right location:

Then secure the remaining two arms with the provided m6xm25 bolts and fender washers:

Reconnect the power plugs to the washer motors:

Finish the reservoir job by reattaching the cap for reservoir filler tube.

IV.Installing the intake tube

Install the Injen sensor grommet onto the intake body. You may need the help of a flat head screw driver to jam it in snuggly:

If you haven’t done so already, install the 60-degree elbow tube onto the throttle body. Ensure that the tube is facing downward, then secure the clamp on the throttle body side:

Next, take the intake tube and insert it into the hole you’ve just made with the installation bracket on the lower end. Carefully guide the tube past the battery until it is aligned with the 60-degree elbow tube:

Tighten the clamp on the elbow tube to secure it with the intake tube.

Align the straight bracket at the lower end of the intake onto the vibra-mount that was used to secure one arm of the Injen replacement reservoir tank earlier, then secure it with the washer and flange nut:

Install the filter and then tighten the clamp:

This step is the best step to install the optional Injen Hydro Shield. It's highly recommended. Make sure you get the 1033 model to ensure fit.

Connect the 18” 17mm hose and press one end over the crank case port and the other over the 3/4” port on the intake:

Connect the 20” 4mm hose and press one end into the brake booster port and press the other end over the 3/8” port on the intake:

Finally, take the air temperature sensor and press it into the grommet installed onto the intake earlier:

Reinstall your battery then reinstall your bumper.

V.Recalibrating your ECU with your new intake system

Remove the ECU fuse from the engine fuse box. Leave it out for 5 minutes. Plug the fuse back in and then start your car.  Allow your car to idle for 10 minutes so your ECU can reprogram itself base on the new intake. Turn off the car and then restart the car.

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  1. Pingback: DIY: How to clean your Acura RSX's IACV (idle air control valve) and throttle body | Balancing Act: A Sojourner's Thoughts

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