101 Corvette Projects

A collection of Do It Yourself projects for the C5 and C6 Corvette

Tag – Corvette C5 Intake Installation

Corvette C5 Vararam Installation

If you have ever tried to install a Corvette C5 Vararam Intake on the Corvette C5 with the factory instructions, you are in for a real treat (instructions are terrible). Cajundude from the Corvette forum compiled much better directions to completing this daunting installation.

Tools you will need:

  • Jack,  jack stands
  • Sockets:  7 mm, 8mm, 10mm
  • Small flathead screwdriver, long flat head screwdriver
  • T30 Torx head
  • Needle nose pliers

Step 1:

Jack up the front of your car or just drive it up onto ramps.  Open your hood and disconnect the negative battery cable.

Step 2:

Removal of the factory air box assembly.  Release the latches on the air box and remove the hose connected to the driver’s side.


There is a goofy clip on the hose and the easiest way to remove that clip is to take a small flat head screwdriver and pry it in gently sliding the teeth of the clamp parallel.



Loosen the clamp around the throttle body where the stock accordion hose hooks up and unplug the MAF.  You can now remove the air bridge and filter.





Pull the lid of the stock airbox off of its supporting studs.  Pull out the two T30 Torx head studs and save in case you want to go back to stock in the future.



Step 3:

Remove the four 10mm bolts holding down the factory radiator cross support, remove it and set it aside.  Unclip the MAF wire harness from the shroud.



Step 3:

Remove the four 10mm bolts (two on each side) holding down the factory radiator cross support, remove the support and set it aside.  Unclip the MAF wire harness from the shroud.



Step 4:

Remove the air dam from underneath the front of the vehicle and place to the side by removing the two 10 mm bolts.  Now remove the access panels to the fog light area.  There is one on each side and each one has five 7mm bolts.

Corvette intake


Corvette Vararam Intake

Step 5:

Remove the fan/radiator/condenser shroud.  There are seven 7mm bolts holding this in.  There are 5 across the front bottom of the car and one on each side.


You will also have to disconnect two plugs and a mounting spot for another.



After you disconnect the plugs you will find that there are two more clips, one on each side of the cover around the lower middle area that are white in color.  To get these off, use a long flathead screwdriver and pry between the middle of the shroud and there mounting spot.  They will pop out of there places and you will remove them from the shroud later.  Remove the shroud from the vehicle.  I found it easy just to pull it up from the top.


Step 6:

Unclip the wiring harness from the bottom of the bezels.  These clips will come out without breaking.  Just squeeze the back side of the clips and push through.


Pull the brake cooling ducts away from the front of the car and push the front end of them towards the outside of the car.  This will free up some more clearance and is pretty much necessary in order to get to one of the bolts on the bezels you remove in a minute.  There is one 10mm bolt for each fog light.  Let them hang off to the side out of your way.  Remove two 10mm bolts from the fog light bezels and remove the bezels.  You will find that after you remove the brake cooling duct you can get a socket through that opening from the front to access one of the bolts easier on the bezel (see pic).


(Brake cooling duct below)



(10mm bolt for fog light below)


Step 7:

Install one of the air scoops.  I used the OEM bezel bolts here without any spacers.  On my car everything lined up perfectly.  Install the air scoop for the other side.




Step 8:

Reinstall your fog lights.  If you think they are misaligned you can do a search for the proper way to align them. Mine seemed to go in perfectly so I am not going to discuss alignment procedures.  The only difference it that the VaraRam does cover up a portion of the top of the fog light, not much, but some.


Step 9:

Take the white clips out of the front shroud with the intention of reusing them.  I took a small flat head and pryed the retainer away a little and worked it off with a pair of needle nose pliers.  Push the white pins back into their original location on the AC condenser.  You can get it mostly in and use a long flat head to push the rest of it in the hole.  Reinstall the shroud and connect all of the plugs in their original locations and replace the retaining clips on the white pins.



Step 10:

Install the VaraRam filter and push it in all the way until it looks even.  This filter goes in with the screen side facing the throttle body.

Step 11:

Pull the elbow out of the stock air box along with the grommet and install it onto the VaraRam box.  Put the grommet in first.  This is a compression fitting so it is difficult to get both in at the same time.  Replace the hose clip you took off earlier.  This simply clicks together now you don’t have to run the teeth parallel to put it back on.  Put on the VaraRam box.



Step 12:

Replace the radiator cross support.  Replace the air bridge, plug the MAF back in and replace the battery cable and you are good to go!



VaraRam suggests around a 45 minute drive at speeds above 55mph to get the PCM to program itself for the extra air.  Alternatively, about three passes at the strip.  This intake yields EXCELLENT RESULTS!

Courtesy of Cajundude from the Corvette Forum

Halltech Corvette C5 Venom Installation

Halltech Venom Corvette C5 2001-2004 Installation Instructions

Donated By Southern Car Parts (www.southerncarparts.com)

Tools Needed

  1. Flat Head Screw Driver
  2. Hairdryer
  3. Freezer

Please note there are two different style C5 Venom Air Bridges that may come with your intake. Do not be alarmed if yours does look like the one in the pictures. You should have one of the two styles shown in the installation directions or look like the one below. There is not any performance difference between either style.

1) Completely remove your stock airbox assembly.

Remove the gray security clip from the MAF connector with a small

screwdriver. You must press down on the small, raised part of the clip

before pulling it off the connector.

Remove the connector by pressing down on its center and then pulling it

off. Tape the connector to the radiator shroud so that it is up and out of

the way.

Remove the 90 degree elbow (AIR hose) and hose from your existing OEM intake. Leave the 90 degree elbow on the hose for now (not shown correctly in picture, picture shows hose disconnected from elbow to aid in illustration).

2) Loosen the 8mm hose clamp that holds the accordion bellows to the

throttle body.

Pop-off the air bridge retainer from the rubber grommets at each side of

the OEM airbridge. See below

3) Remove the air filter and its frame from the airbox. This will allow you to

see the grommets that are keeping the airbox attached to the front part of

the car.

4) Now that you can see the attachment points, reach down near one of the

grommets and pull the front of the airbox toward the engine. Watch the

retaining pin slip through the grommet. Now repeat for the other side’s

grommet.

Pull the accordion bellows away from the throttle body and remove the

OEM airbox and bridge assembly. You’re halfway there!

Below is a picture of the entire stock airbox assembly removed from the car.


5) Remove the airbox hose end and the airbridge end from the MAF sensor by first

loosening the band clamps and then twisting and pulling. The airbox end will slip

out rather easily, but the airbridge end may take a bit of muscle to disconnect.



6) Take the stock MAF and place it in the freezer. Grab your new Halltech airbridge and a hairdryer. Using the hairdryer, warm the MAF end of the airbridge (end that does not have the rubber coupling on it). See below.


7) After a minute of warming, pull the MAF out of the freezer and attach the rubber coupling that came with the Halltech to the back side of the MAF (notice the airflow direction arrow on the MAF) The rubber coupling goes on the side that the arrow points too. Also make sure you line up the notch on the rubber coupling to the notch on the MAF. Lay it on a countertop or flat surface, rubber coupling down and front of the MAF facing up. (see below)


8) Take the warmed airbridge and slide it over the MAF, pressing down firmly until it is seated in place. You might need to warm the plastic some more with the hairdryer. The finished product should look like below.


Now to install in the car. Place your new filter (plastic removed) into the engine bay where the old filter assembly was.


9) Grab the entire airbrdge assembly and connect the MAF end to your intake manifold.



10) Using the band clamps, tighten the rubber coupling to the intake manifold.


11) Next, go to the front of the car and reaching in from under the hood, slide the filter into the other end of the airbidge and tighten the airbridge and filter together until they are snug.


12) Disconnect the clip that holds the MAF cable to the shroud, can be a little tricky as it has a little latch on it.


You should now be able to get some slack in the MAF plug and be able to plug it back into the MAF, do not forget to put the little grey locking piece back into the plug.



13) Last but not least, *****Updated 1/31/08**** There is now two versions of the Venom in the marketplace. Please pull out your air filter from the box and check on the bottom of the filter for a small hole. If you have the hole on the bottom of your filter skip this section and jump all the way to step 13A, if not continue on to step 13 skipping steps 13a and b..

13) Next remove the plastic elbow from the A.I.R hose (one you left on in step 1). You can set it aside as you will not need it anymore. Reusing the clamp that was on the hose. Insert the small filter that came with your Halltech into the A.I.R. hose and clamp into place. You can just lay the hose with the filter down by the Halltech filter.







13A) Only use step (13a and b) if you have a hole in the bottom of your air filter. Skip this step if you intake filter does not have a small hole in the bottom of the filter and came with a small air filter and one large one.

13B) Insert the elbow of your AIR hose (the one you left on in step one) into the bottom of your filter so that it looks like below.


14) That is it, clean up and enjoy the power of your new Halltech Intake.

Finished product


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