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Old 30th April 2011, 12:11 PM   #1 (permalink)
charles charlie is chasing a Veyron from 30-130mph
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GTC INTAKES install guide

GTC Intake Install guide


Background:

My GTR has been running a custom tune from Ben at GTC for the last 18 months or so, and is usual for me, I'm always on the lookout for a little more messing around with my car.

I decided a few months back that I would install some new intakes but only if there was going to be an improvement in power and response. Otherwise, I thought, what is the point.

So, I had a chat with Ben who was as helpful as ever and so I decided upon his shiny intakes but with ITG foam filter rather than K&N cone filters.

My reasoning was..

1. They require a remap after install to prevent the car running lean, which clearly shows they are more free flowing than the K&N filters and should lead to a little more power.
2. Being foam should mean an easier install without having to remove the bumper.
3. They are made in the UK, always a bonus!

I also added some Outerwear pre-filter filters bought off ebay for £40 as a added layer of protection for the filters. They are designed for the ITG JC10R TALL FILTER but fit the GTC supplied filters perfectly. There is no evidence that these are needed for normal conditions such that we have in the UK, but I felt these would keep my filters cleaner for longer.

Tools required:

9mm, 10mm and 12mm sockets and suitable ratchet
Small flat bladed screwdriver
7mm hose clamp driver
Phillips head screwdriver

...and time to do this. Bear in mind that once you have removed the OEM boxes, you cannot drive the car before installing the new intakes, so make sure you have sufficient time to finish.
I would have taken half the time had I had my guide. Some of the guides out there suggest you dismantle half your pipework, which frankly is just not necessary.

Time required: 2-3 hours tops

Difficulty: Easy – Moderate


VERY VERY IMPORTANT!

Fitting of these intakes with ITG filter requires a remap of your ECU, in my case using a COBB AP and Ben at GTC's ingenuity in order to prevent the car running lean which potentially could be damaging for your engine.


Here we go!

STEP 1

Take your ITG filters out of the box (keep the plastic packaging bags they came in) and spray each one with approx ½ to ¾ of a can of oil (use only the supplied oil) onto the foam of the filter. Place in a dust free spot to dry out. Once dry, pop the Outerwear cover on and put back into the plastic bag the filters came in as this will protect the filter (and your hands!) when we install the filters later. The picture below shows the filter oiled and my silicone pipe installed. DO NOT put any silicone pipes on yet as install is easier if we do that later.


STEP 2

Bonnet up, remove the cooling plate by lifting up the tabs using a flat screwdriver as shown..



Remove the plastic plate and put aside.

Now look down behind the bumper and you will see this..

We will also remove the metal air guide (red arrow) to make installing our filters easier.
Remove the plastic tabs circled and pull the plastic intake guide forwards towards the yellow arrow.


Remove the bolt shown below using a 12mm socket and pull the metal guide upward and out.




STEP 3

Now we will be disconnecting the OEM airbox and removing it from the engine bay.



Unclip the MAF sensor wiring and push to one side

Undo the 2 10mm bolts lateral to the airbox which hold the airbox and its mounting bracket to the car



Next loosen the 7mm hose clamp at the back of the airbox which connects it to the flexible rubber tubing of the turbo inlet.

STEP 4

We now need to create enough room for the airbox to be easily removed from the engine bay.
The simple way to do this is to undo the recirc valve and free the grounding cable above the airbox by undoing it from the engine block and pulling it towards the side of the car.

Undo the recirc valve by removing the 2 x 9mm bolts holding it onto the recirc pipe TAKING GREAT CARE TO REMOVE the GASKET AND KEEP IT SAFE (red arrow). Push aside.


We now need to loosen the grounding cable (yellow arrows below)

by undoing the bolt circled below and pulling the cable back through the retaining clip in the direction of the green arrow.


STEP 5

Now with a big heave-ho pull the OEM airbox upwards and out. It is held in by 2 rubber grommets underneath which require a little strength to release.
You should now be left with the turbo inlet


Once out of the car, undo the MAF sensor and its retaining plate and transfer over to your new intakes CAREFULLY. Do not drop the sensor or touch the wire on it's inside portion. The plate and sensor are held in place by the original screws and ENSURE THE SENSOR IS PLACED THE CORRECT WAY AROUND IN THE AIRFLOW, as it was on the original pipe.


STEP 6

Pull the turbo inlet pipe towards the front of the car (towards the yellow arrow)

and marry the new intake pipe to the rubber connector. Dont tighten anything yet!
Next step is to push the foam filter in behind the bumper and then slide on your silicone pipe (with a hose clamp on it already but not tightened) by pushing it from the engine bay side towards the filter.
You can then slide the silicone pipe over the filter and tighten the clamp.
Pop another clamp over the silicone pipe from inside the engine bay and slide this silicone pipe onto the intake pipe.
Once connected tighten all the clamps (2 on the silicone pipe and 1 on the turbo connector) and ensure the intake is secure.
Re-attach the MAF wiring connector.
If you left the plastic bag on the filters to save getting oil everywhere, pull that off your filter now.

STEP 7

Finish off by

pulling the grounding wire back over and reattach the bolt to the engine block.
Re-attach the recirc valve and gasket

Re-check your clamps and bolts and do the other side exactly the same as above.


Finally....

The remap that Ben has done combined with these intakes makes the car smoother and definitely seat of the pants faster. Sound is a little different but with a 90mm Titan at full chat, I cant ear intakes at all!
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Old 30th April 2011, 12:28 PM   #2 (permalink)
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You made that look so easy

Great work and detail thanks for sharing
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Old 30th April 2011, 12:39 PM   #3 (permalink)
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Nice one CC. Need more guys like you. PM`d you in respect of something else
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Old 30th April 2011, 12:43 PM   #4 (permalink)
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Well done CC, Will be very useful as I just waiting for my set from Ben

Dave.
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Old 30th April 2011, 04:28 PM   #5 (permalink)
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A most excellent and brilliantly documented write up CC - can't see me doing it though as I like someone who knows vaugely what they are doing in my engine bay!!
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Old 1st May 2011, 12:57 AM   #6 (permalink)
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Great write up CC as per usual
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Old 1st May 2011, 01:25 AM   #7 (permalink)
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Great guide, and great photos,
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Old 1st May 2011, 12:31 PM   #8 (permalink)
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My intakes are in the care of parcelforce at the minute. Once they arrive I will have tools and this guide at the ready.

Will let you know how easy they are with the guide.
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Old 1st May 2011, 07:29 PM   #9 (permalink)
charles charlie is chasing a Veyron from 30-130mph
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Quote:
Originally Posted by baileyconstruct View Post
My intakes are in the care of parcelforce at the minute. Once they arrive I will have tools and this guide at the ready.

Will let you know how easy they are with the guide.
Dont forget to give me a call if you need any help, as long as it's on a weekend!
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______________________________________


Engine built @ RiversideRacing
Litcho rods/pistons/RaceIC/BOVs/oil cooler/susp+handling kit/front diff
Race Developments ported manifold/AT Power TBs
RF street zorst+DPs
RacingBrake BBK
Xtreme18 Clutch/Dodson 1st gear+shaft/trans brace
2015 alloys/nav upgrade/Nismo cluster
DSC susp controller
DBA front/Varis CF bonnet/2016 Lights
TTE7XX turbos = >900bhp 700lbsft 30-130mph in 8.19s



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Old 1st May 2011, 08:29 PM   #10 (permalink)
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Quote:
Originally Posted by charles charlie View Post
Dont forget to give me a call if you need any help, as long as it's on a weekend!
Cheers and may take you up on that offer.
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Old 1st May 2011, 10:25 PM   #11 (permalink)
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Exclamation

"Spray each one with approx ½ to ¾ of a can of oil (use only the supplied oil) onto the foam of the filter"

Im sure Im correct in saying the R35 uses AFM`s, in which case id be rather concerned about the oil contamination the sensor!

Even the light oiling i gave my K&N's eventually killed one of my afms which in turn took out both of my turbos! !!!!


Id personally run them with as little oil as possible, 1/4 can would be more than enough for both filters.
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My R32's full restoration:

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Air Filters:

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Old 1st May 2011, 10:35 PM   #12 (permalink)
charles charlie is chasing a Veyron from 30-130mph
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Quote:
Originally Posted by Scott View Post
"Spray each one with approx ½ to ¾ of a can of oil (use only the supplied oil) onto the foam of the filter"

Im sure Im correct in saying the R35 uses AFM`s, in which case id be rather concerned about the oil contamination the sensor!

Even the light oiling i gave my K&N's eventually killed one of my afms which in turn took out both of my turbos! !!!!


Id personally run them with as little oil as possible, 1/4 can would be more than enough for both filters.
ITG are very, very specific about oiling their foam filters which are not like K&N filters at all, and as such your experiences may not carry over to this application.

ITG foam filters must be oiled to achieve the level of filtration and their testing show NO OIL reaching the MAF sensors.

ITG info here

So, previous experience with other brands of foam filters do not apply to ITG and their unique design.

The ITG filters used here are huge and Merlin Motorsport actually advised me to use 1 can per filter, so I reduced that!
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2015 alloys/nav upgrade/Nismo cluster
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TTE7XX turbos = >900bhp 700lbsft 30-130mph in 8.19s



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Last edited by charles charlie; 1st May 2011 at 10:43 PM..
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Old 1st May 2011, 10:40 PM   #13 (permalink)
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I've been design air induction systems for 16 years now and i can assure you differently.

Click on the second link in my signature.


Just go easy with the oil.
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Old 1st May 2011, 10:42 PM   #14 (permalink)
charles charlie is chasing a Veyron from 30-130mph
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Quote:
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I've been design air induction systems for 16 years now and i can assure you differently.

Just go easy with the oil.
Then please let ITG know as their advice is as above!

Have you used ITG filters before?
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RF street zorst+DPs
RacingBrake BBK
Xtreme18 Clutch/Dodson 1st gear+shaft/trans brace
2015 alloys/nav upgrade/Nismo cluster
DSC susp controller
DBA front/Varis CF bonnet/2016 Lights
TTE7XX turbos = >900bhp 700lbsft 30-130mph in 8.19s



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Old 2nd May 2011, 12:39 AM   #15 (permalink)
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Great write up CC. I will never ever do this but it's good that the forum has people like you who take the time to help other owners with this kind off stuff. Keep up the good work
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Old 8th May 2011, 12:23 PM   #16 (permalink)
charles charlie is chasing a Veyron from 30-130mph
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Cheers and may take you up on that offer.
My mobile never rang so how did you get on?
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RF street zorst+DPs
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Xtreme18 Clutch/Dodson 1st gear+shaft/trans brace
2015 alloys/nav upgrade/Nismo cluster
DSC susp controller
DBA front/Varis CF bonnet/2016 Lights
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Old 8th May 2011, 12:55 PM   #17 (permalink)
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My mobile never rang so how did you get on?
I have backed out doing it as I am letting svm do it when they install my y pipe and Titan exhaust.

However I had a dry run with your guide and I felt confident I could have done this in about 1hr a side.

Now that you have had them on for a bit do you feel them giving you extra power?
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Old 8th May 2011, 02:48 PM   #18 (permalink)
charles charlie is chasing a Veyron from 30-130mph
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The car feels smoother, more refined with better torque lower down the RPM. Not a huge difference compared to the jump from stock to custom tune, but a decent improvement all over the powerband.

A worthwhile mod imho.
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RF street zorst+DPs
RacingBrake BBK
Xtreme18 Clutch/Dodson 1st gear+shaft/trans brace
2015 alloys/nav upgrade/Nismo cluster
DSC susp controller
DBA front/Varis CF bonnet/2016 Lights
TTE7XX turbos = >900bhp 700lbsft 30-130mph in 8.19s



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Old 13th May 2011, 01:07 PM   #19 (permalink)
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Like this comment from Ben's website

Designed to be easy to install without having to modify your car or remove the front bumper. Installation requires no cutting or trimming or removal of the bumper or bumper support and can be completed with simple tools. Simply remove the stock airbox and bolt the GTC intake into place in just minutes!

Going to do mine this weekend

Dave.
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Old 14th May 2011, 09:11 AM   #20 (permalink)
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Thumbs up

Job done & well worth the effort Took a little over an hour with CC's & Ben's instructions

Now what comes next?

Dave
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