Volant install w/ Powercore, pics (lots) + problem, solution (hope so) & writeup

Volant CAI install, 08-10 Kit for the Frontier.

Installed on 2009 Frontier PRO-4X, 6spd, with headers and true duals.

First things first. Before I did anything, anticipating problems, I installed my Scangauge II into it's temporary home. Tigger guards it with his life...



This is a great little tool and I highly recommend anyone thinking about getting one to stop thinking about it and get one. Now, on to the install of the Volant CAI.

TOOLS (What I Used):
Phillips and Flat Head Screwdriver
Vise Grips (Excellent for the spring clamps)
1/4" Ratchet (All Bolts Except Center/Bottom Airbox)
3/8" Ratchet (Center/Bottom Airbox Bolt)
4" Extension (Approx. Length to reach Horn Bracket Bolt)
8mm Socket (Hose Clamps)
10mm Deep Well Socket (Battery Terminal)
10mm Standard Socket (Bolt by brake lines and Volant Horn Bolt)
10mm Wrench (Nut on Volant Horn Bolt)
12mm, 12 Pt Standard Socket (Horn Bracket Bolt)
13mm Standard Socket (Middle Bolt and Bottom Bolt)

Step 1) I did as much work as I could before opening the hood. This included putting on the connector from the tube to the airbox, removing the Powercore filter, fixing the edging to where the airbox meets the fender (trimming required, see below) and drilling a couple of drain holes in the bottom.









Step 2) I had installed a K&N intake so this is what we were starting with. That all had to be removed. If you have a stock intake you'll need to remove that along with the studs in the fender that the stock intake attach too (we'll get to that.) On mine, I had also removed the screw that holds a ground wire, this had to be re-attached. Lesson: NEVER throw away OEM parts. They can be very useful.





Step 3) Unhook the negative battery terminal.



Step 4) Disconnect the MAF sensor and place it somewhere safe.



Step 5) Loosen all the hose clamps, bolts, hoses (crank case vent + front diff breather if stock.) If you have an aftermarket intake you can now remove it. If you have a stock intake you'll have to pull up (sort of hard) to get the stock airbox off the studs. Once you've got it out, this is what you have... Emptiness (also of note I put the connector for the Volant on the throttle body. This is a mistake. Attach that to the tube first, it'll make life easier.)



Step 6) Once you've got a blank canvas to work from the fun begins. I honestly didn't believe everyone when they said this was a PITA but rest assured it is. Only two bolts lineup even close if you're planning to relocate the horn the way Volant appears to want you to. Unbolt the horn and also unplug it. Turn it on it's side and place it on the airbox the only way that makes any sense (and it's little sense at that.) Place the bolt with washer through the mounting hole and place the washer, lock washer and nut in the backside (inside the airbox.) DO NOT tighten down. Leave it moderately loose. Pry, jam, twist and shove the airbox into the general area it's supposed to go. The horn bracket will straddle the back of the headlight bulb plug and just miss the corner reflector/driving light. Continue prying and shoving until you can get the middle bolt sort of lined up, hold the airbox tight and put a socket/ratchet on that bastard and tighten it to where the bolt won't pop back out. Next put the top bolt in and tighten that down. Give up hope now of getting the bottom bolt in. Finally, tighten down the horn bolt (the airbox will bow a little bit.) NOTE: I did not do it, but it might make life easier to pull the drivers side headlight out if you're going to install the horn like Volant suggests.





Step 7) Install the intake tube. This is when I placed the MAF sensor into the tube. I used the Volant supplied gasket. There was a little gap between the gasket and the bottom of the MAF where the screws go through so that was taken up by a couple nylon washers to get even pressure across the thing.

**Step 8 )** Install Powercore filter or whatever filter you've chosen.



Step 9) Install crank case vent hose (I reused the one from the K&N and utilized the factory spring clamps. I recommend dispensing with the Volant nonsense and going and getting some good hose.) Reattach the MAF sensor.



Step 10) Go back over every hose clamp and tighten those babies down nice and snug (8mm socket.)

Step 11) Put the lid on the intake, button her up, reconnect the negative battery terminal and be **happy**.



I had taken a preliminary IAT reading at idle. The K&N was 98*F, the Volant with Powercore was 94*F after running approx. 2 mins. I hopped in the truck and took it for a good 45 mile test drive. Torque was nice, pull was good and there were no signs of problems. Idle was dead on where it should be. I thought to myself SUCCESS!!! The damn thing might actually be worth all the work.

**Today I drove home (upstate NY) from CT. After 230 miles of driving, the SES came on. Truck's idle was slightly strange. Not unexpected from all that I've read. This is why I installed the Scangauge. Got to my GF's Mothers, checked the code, PO171, no surprise. Cleared the code, shut off the truck, opened the hood. Tore out the Powercore filter, gave it what was coming to it, and reinstalled the AEM I ran on the K&N. Fired the truck back up and the idle was gold.**





Overall, I give the Volant a 5/10 based SOLELY on the install and the repeated SES problem. It's a CAI for Christ sake not a Camshaft, there should be no need for a tune or any other nonsense. It honestly looks like they never even looked in the engine bay of one of these trucks. K&N, install was straight butter, less than 45 mins start to finish. Volant, install was 3 hours fighting with the goddamn horn and airbox bolts to get it in. Mind you I was determined to do it the way Volant appeared to want it. Not impressed with their "engineers" and since I am one, I know the work that's supposed to go into these sort of things in the prototype to get all the bugs worked out before mass production starts. They skipped that part.

I had taken more pictures but Photobucket is being dumb and keeps erroring out when uploading them. I will update this thread as I get more data with the Volant/AEM combo.