COLD-AIR INTAKE 93-97 4AFE Corolla

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COLD-AIR INTAKE
The aftermarket intakes available for the 93-97 4AFE Corolla will fit the AE92 sedan, but you're even better off making your own. The cheapest an easiest DIY intake is just a K&N cone filter at the end of your flex pipe, with a heat shield protecting it. This setup provided the quickest throttle response and actually gave me more power than the 2 inch diameter pipe, filter-in-the-bumper setup I tried. Later I switched to 3 inch diameter.

You have two options for routing a cold-air intake. For both I recommend moving the battery to the trunk as explained in the CHASSIS section. If visual smog checks aren't a problem for you, cut down the rubber from the flex part of your throttle body just enough to accept the pipe and contain your IAT sensor. Not-using your IAT sensor will hurt your car's performance at the very least. If smog is a problem, you can at least remove the three air chambers on the flex pipe and plug them. I'm pretty sure they're just to quiet the intake sound. Remove all of the intake chambers in the engine bay and inside the fender. You will need a new place to mount your diagnosis plug. Keep all your stock parts and put them back on for smog checks. Go to www.4AGZE.com and www.ae92gts.com for other options.

My method requires some kind of 2.75 - 3 inch diameter straight pipe with a 120 degree bend at the end. 2.75 inch will fit nicely into your flex pipe and after some minor cutting there is 3 inches max of clearance between the unibody and headlight bracket into the bumper. I think the length of the pipe without the bend is 1 ft 9.5 inches. Preferably it should be thin, non-corrosive metal wrapped in heat tape, but even plastic that is somewhat heat resistant will work. Wrap the heat tape longways. Don't try to wrap it like a candy cane or you'll crinkle the living fuck out of it. A quick safari through Home Depot will turn up material for making a heat shield. You want something that doesn't conduct heat well.

The cutting involves some sheet metal snips and a pry. Remove the headlight and bracket but don't touch any of the headlight adjustment screws. Cut the useless sheet metal that extends from the unibody behind the headlight. Then seperate the headlight from the bracket and pry off the piece that redundantly secures the turn corner lens. Cut off the lower corner, fitting it back to the car and jamming your pipe against it as a reference as to where to cut. Shove your intake pipe into the throttle body flex pipe and secure it with a clamp. At the other end of the pipe, you have a 120 degree bend fit between the cut-out unibody and headlight bracket. That bend is then shoved into an oval shaped K&N filter, which hangs down into your bumper. It is a good idea to secure the pipe and filter with mounts or clamps to your car, although I haven't had much trouble with it rattling or moving around. Put your headlight and everything else back on and then unplug your battery for a few minutes to reset the ECU.

You can cut out sections of your bumper for ram air and put some kind of tight gapped grill that will limit the amount of and pressure of water that splashes on it. It's a good idea to vent air into the bumper around but not directly on the filter. This will raise the air pressure and it will be practical for street applications. Otherwise grease quickly builds up on the filter. Water splashing directly on the filter at a high speed will go right through it. It is unlikely that any water will make it into your combustion chamber, but if enough water vapor does complete this happy little journey you can kiss the engine goodbye. If you completely submerge the filter or if the filter becomes almost totally restricted, your car will stall. I have never had any problems in wet weather or driving through small puddles, but I advise that you use common sense and consider moving your filter up into the engine bay (as per my first intake suggestion) temporarily during wet weather. It's easy to fit the filter directly to the flex pipe on the throttle body using a short piece of pipe and a clamp.