[novolvo]

Probably not many folks left here putting K&Ns on 04s, but I just added one today and have a tip for anyone who happens to be searching for help. The steps listed in the instructions are a little out of sequence. If you bolt the black shield to the fender before connecting the filter to the MAF, it is extremely difficult (impossible?) to get the silicone hose to fit into the MAF. It is much easier to leave the shield unbolted until you've got all the filter/MAF/intake tube connections made. The shield has to be set in place in order to run the end of the filter through it...just don't bolt it down until the end. Hope this helps someone some day! :cheers

 

[Xman]

Now you need to make it a true CAI by blocking off the "leaks" that let hot engine compartment air be ingested. I got the K&N CAI because it had a heat shield. However, it has several open areas for engine bay air to get past. So I purchased some ThermoKing insulation at Lowe's and opened up a larger air passages. I've been doing great during the hot Texas Summer!!

Here is where I made a larger opening in the fender so the engine would draw air in from behind the fog lamp.

Also, modified the K&N bracket to prevent chaffing the power steering hose.

Here is the "air box" area before the filter and induction tube goes back in. I used GM touch-up paint I had to make sure there was no bare metal.

Also blocked the rest of the openings to make it almost air tight with the hood down. I had to use a plastic tie wrap to keep the foam to stay put around between the shield and the filter.

I worked the adhesive-backed insulation blanket around the induction tube and made sure it was secure with some 18-inch tie wrapes. Total cost was $16. I don't have a thermo couple to take measurements but I know this has got to provide a significant benefit. I've been configured for several months like this and the commercial foam products have showed no sign of not being up for the job - including some track time. I've also added some more insulation around the IAT sensor to make sure flow off the radiator is not affecting it.