K&N 57i-7504 Manuel D'instructions

Kit Number 57i-7504
MG ZR160, 1.8L L4 16v 158 bhp, 2001-
Instruction sheet A2054-639
1. Disconnect the negative terminal from the vehicle battery.
2. Unclip & remove the flexi intake hose from the throttle housing. (Fig. 1)
3. Unclip & remove the air box lid from the base & remove the assembly from the vehicle.
(Fig. 2)
4. Remove the 2 bolts from the side of the air box base & carefully remove the base assembly
from the vehicle. (Fig. 3&4)
5. Unclip & remove the air box intake scoop assembly from the vehicle. (Fig. 5)
6. Reposition the harness which was secured to the intake scoop & secure to the earth strap
using a plastic tie (this is to give added clearance for the heat shield fitment). (Fig. 6)
7. Remove the front most camshaft / VVC end cover securing bolt. (Fig. 7)
8.
9. Fit the edge trim to the heat shield as shown. Remove any excess trim if necessary. Fig. 9)
10.
nylock nut supplied. (Fig.10)
11. Pierce / drill two holes in the top of the flexi cold air hose to match the holes in the bottom
of the heat shield. Attach the flexi hose to the hole in the bottom of the heat shield using 2
plastic ties supplied. (Fig.11)
12. Taking the necessary safety precautions as per manufacturers instructions raise the front of
the vehicle. Feed the cold air hose down to the lower spoiler & secure the hose to the sub-
frame using the plastic ties supplied. (Fig.12)
13. Assemble the molded intake pipe using the silicone hose, rubber filter adaptor & hose clips
supplied. Fit the new filtercharger onto the rubber filter adaptor & tighten the #64 hose clip
supplied. (Fig.13)
14. Present the new intake assembly to the engine & attach the new intake pipe to the throttle
housing using a #44 clip supplied (do not fully tighten the clamp at this time). (Fig.14&15)
15. Fit the studded lid of the filtercharger to the slotted hole in the front of the heat shield using
the plastic spacer supplied. (Fig.16)
16. Set the height of the filtercharger on the slotted hole, then secure using a nylock nut &
washer supplied. (Fig.17)
17. Now tighten the hose clamp securing the intake pipe to the throttle housing.
18. Reconnect the negative terminal to the vehicle battery.
19. Carry out a final check of the height / alignment of the K&N induction system before starting
the engine. Installation is now complete. (Fig.18)
Fig. # 1
Fig. # 5
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Fig. # 2
Fig. # 6
UK technical enquiries: phone the R&D department at 01925-635950, Mon-Fri from 9 am to 5 pm
Parts list:
1 x Fixing Kit :-
WARNING: Before starting the
engine carry out a final fitment check
of the K&N performance kit. It will be
necessary for all intake systems to
be checked periodically for
realignment, clearance and
tightening of all connections. Failure
to follow the above instructions or
proper maintenance may void the
warranty.
FILTER MAINTENANCE: K&N
suggests checking the filter periodi-
cally for excessive dirt build-up.
When the element becomes covered
in dirt (or once a year), service it
according to the instructions on the
Recharger service kit available from
your K&N dealer, part number 99-
5000 or 99-5050.
Fig. # 3
Fig. # 7
Technical Support: eindhoven.tech@knfilters.com
1 x Filtercharger Element.
1 x Plastic Intake Tube.
1 x Rubber Filter Adaptor
1 x Stepped Silicone Hose.
1 x Heat Shield.
1 x Flexi Cold Air Hose.
1 x Edge Trim.
1 x Literature Pack.
3 x M6 Flat Metal Washer.
2 x M6 Nylock Nut.
1 x M6 Hex Head Bolt.
1 x Nylon Spacer.
2 x Hose Clamp #44.
5 x Plastic Tie.
Fig. # 4
Fig. # 8