I assembled and installed a home made open air induction set up on my 02 PSD. It was quite easy and I was looking forward to the results but was extremely disturbed when I heard the outcome. The turbo stall, surge which i was prepared in advance to notice turned out to be too take. It literally sounded like the engine was falling apart under the hood. I have it strait piped and maybe thats why its so loud but i ended up taking it off. Any help would be appreciated as I would like to reinstall if what i'm hearing is normal !!!!

 

I assume you made something similar to the tymar....if that is the case....yes there is a noise. it bothered me at first too. I don't know about yours, but mine is a high pitched whine/shrill. It only happens when I get on the pedal. Most noticeable between 4th gear and O/D once I hit about 2300 rpms....it will stay there until you let off the gas or until it shifts. the first time or two when I got around 3000 rpm, I couldn't believe the noise. I think mine has quitened down a bit. Don't know if its because I don't try to push it as much, or because the onboard computer has adjusted somewhat.

the sound you hear is normal, but the filter does its job. I have had mine on since 9/03 and about 8,000 miles. no problems and doubt I'll ever go back to stock.

 

I've also been looking at building a home made version of an air induction system. I've heard rumors of instuctions floating around somewere with part numbers from Napa and other hardware stores. Were did you get your parts from? Do you have instructions for this? Also could you explain to me what turbo stall/surge is? Is this something that could damage my truck? I have also heard that these home made filters are comparable to the tymar intake, does anybody have any opinion or input about this? Sorry for all the questions just triing to expand my knowledge of this issue.

 

To answer the latter question surge and stall is normal, and not going to hurt anything, the reason i mention it is because the open air setup since only a couple of feet from the compressor wheel tends to make the noise of surge and stall extremely amplified where as almost inaudible with the stock setup. anyway to answer your question, I have an 02 and all i needed was one 4 1/4 inch automotive clamps and a 3.5 inch long 4 inch diameter piece of exhaust pipe. Of course the variety of filters available is completely up to you. I could not find a single Donaldson, Baldwin, Napa, Cummins, filter anywhere here in ablilene tx, so I ordered a Wix and i cant remember the part #. However the Purolator filter I did find but will not work on the setup as it does not come with the 4 inch diameter flange needed to clamp to the pipe.

The assembly is simple on mine. Unplug the filter minder, and air intake temp sensor on the stock box. Then disconnect the battery cables, remove the battery cover, unsnapp all the snap connectors on the old box, then remove all the bolts (four of them holding the fiter box in place). Then using the factory clamp, install the 3.5 inch 4 inch diameter pipe into the intake hose. Then install the filter to the other end of the pipe and clamp down. With the exception of your own choice of filter bracing methods you are finished and put everything back together..

A couple of things to make note of though,

My application did not involve the removeal of the stock battery tray

the length of the piece of exhaust pipe needed may vary depending on the filter You choose to use

with my set up, the filter rested snuggly against the fender needing no brace, but the filter was so big that the hood when closed would bend a portion of the metal mesh covering on the filter. Did not hurt anything just an indication of how snug the fit under there was with the Wix Filter.... When I get the part # for the filter i will forward it to you.

I would suggest you get the filter you want first then play around with it to determine the length of pipe you will need. I had to cut mine down a couple of times to make it fit....... Good luck.

 

napa filter # 6637

 

What is the recomendation for a good filter? Is either the Wix or the Napa filter #6637 a reusable filter? Is it known which one flows better? How much are they? Sorry, I'm just gettin all excited to add this to my truck. Thanks for all your help!

 

With this home made setup.. Do you need to do anything with the sensor thats in the stock air box?? Thanks...

 

no, they are not reuseable. They go anywhere from 15,000 to 20,000 miles before changes though. depending on where you get them from your looking at $25- $30. I chose the Donaldson becaue that is who did the new powercore filter for the 6.0....and they know filters. don't know about a comparision chart though. you love it......just do it.

go to the top of the page and click search....put in tymar filter and the 7.3L forum to search in....go as far back as 6 mos...and you will have more reading, part numbers, opinions, and ideas then you care to read about. I waded thru it all before deciding...but it helped me understand it all. the whole surge/stall discussion is there too. good luck.

 

no...just zip tie it up out of the way. since your filter is under the hood its okay if it reads those temps too.

 

I have a 2002 made in December of 01, and it looks like the battery and the air filter are the same box. Did they come apart for you?

 

I just did mine: Piece of 4" ex pipe, Napa 6637 filter, cable tie the sensor.
Noticed a difference in acceleration right away.
Noticed the turbo noise, too--but not too bad on mine.
Good luck.

 

i have a picture or 2 in my gallery of my setup just fyi

 

so2315

the filter box on mine came right out after removal of the bolts attatching it to the battery tray. Be sure you have unsnapped all of the little snap things all the way on the motor side of the filter box. I did notice that after unsnapping a couple that after moving on to the next that they would snap back together themselves and it will not come out with even one still snapped.

I hope you get her figured out but it should have been fairly simple unless our 02's are different. I wouldn't thinks so though. I'm not completely sure but i think mine was made in June or July 02. Who knows they very well could be different???? Good luck and feel free to e-mail if you need to!

Sorry, My engine was made in July 02, I have no Idea about the truck, how can you tell?????

 

Ok I know from reading posts that I'm going to take a beating on this but I'm currently running a K&N flat pan filter. Will i notice a difference in acceleration and throtle response from the K&N to this home made set up? From everything I've read I know that I should get rid of the K&N.

 

I would think you would notice a difference....probably not as great as the others, but since your still using the stock air box, you are still somewhat restricted....the open air filter takes in about twice what you can get in your current filter. PLUS --- you don't have to worry about dust particles making it thru ...you said you knew it was coming...just didn't want to disappoint you!