VARARAM TCR-7 Installation Instructions

Toolsneeded:10MMdeepsocketw/a6inchextensionPhilipsheadScrewdriver7mmsocket5/16thssocket

Readtheinstruc2oncompletelythroughBEFOREbeginningtheinstalla2on.Inthebackoftheinstruc2onswehaveincludedsomecompletedoverheadviews.Ifyoufeeluncomfortabledoingthisinstalla2onpleaseconsultacer2fiedservicetechnician.

RemovingRadiatorduct:Usinga7mmsocketremoveall4bolts.

Removeintaketube:RemovePCVline/lines(1or2linesdependingontheYR)Squeezetorelease.showninimageUse5/16thsocket,loosenthethroMlebodyclampandtheclampontheair-boxneck.Removetheintaketube.

Removeintaketubeprt-2

Separatortank

RemovingtheAirbox:UnlockandunplugtheMAFharness.(asshowninMAFdisconnectimage)Usinga10MMsocket,removebothAir-boxboltsaspicturedinimage#1and#2.It’sbesttousetheextensionontheboltclosesttotheradiatorsothatyoucangainaccessunderthehoodshock.1.  Nowremovethesecondbolt.2.  LiVoutfactoryairbox.

#1

#2#4

PassengersidePCV

DriverssidePCV

MAFdisconnect

RemovechromeAir-boxknobontheinsidefenderbelowthesecondairboxbolthole.(10mmdeepsocket)

RemovingMAFsensor:RemovethesensorusingaPhilipsheadscrewdriver,somemodelyrs.mayuseastarpaMernscrew(#21).Makesuretoremoveandre-usetheBlackSquareshapedringsealfromtheMAFsensorontheVRIntake.

Airboxbolthole

Chromeknob

InsertMAFsensorintoVRunit-Re-usethesquareringsealbetweenthesensorandtheVRunit.UsetheVRsuppliedscrewstoYghteninplace.DONOTover2ghten!

InstallfoamstripwithadhesivebackingPeeloffred3MandsYckontotheframe,followingtheoriginalAir-boxlineasshown

Installbubblestripwithadhesivebackingontothelowerfrontsec2onoftheVRunitasshown.Thisisrequiredforapropersealandperformance.

FRONTofCAR

_______________________________

InstallingtheVRunitintoplaceasonepiece-ReadthroughthissecYoncompletelybeforebeginning.Placeallbandclampsontheunitasshown,leavingthebandclampsthatsecuretheintaketubetothebackoftheAir-boxfingerYght,but,Yghtenoughtoholdthetubeonasshown.Alignthefrontairboxboltholefirst.RuntheboltinsnugbutdonotYghtenitcompletelyyet.Runinsecondboltanddothesame……..NowstarYngwiththefrontboltYghtenbothboltscompletely.ThefrontsecYonisdesignedtoflextoshapetothefendertoformaproperseal.

Centerclamps

SlideintaketubetailhoseontothethroMlebodyandYghtentheclampcompletely.

ThiswillpulltheJointbetweentheAir-boxtailandintaketubeinoppositedirecYonsandSETtheintaketubeandAir-boxjointangle(asshownbelow)FeeltheendoftheintaketubeandslidetheclamptothisareaandYghten(sparkplug2ghtonly)NowYghtentheAir-boxneckclamp(sparkplug2ghtonly)

JOINT

Clamps

Aquickdoublechecksteptocheckyourwork-Removethesystemasoneunit,leavingJOINThoseclamps2ght.OnceremovedrunyourarminfromthethroMlebodysideandFEELforthetransiYonattheAir-BoxtailtointaketubeconnecYon(asshown)feelforanygapsontheshort-sideradius,ifsoslidetheintaketubeclampdownfurtherandre-Yghten.Re-Installthesystemasonepieceasbefore.

FEELHERE

PlugintheMAFsensorharness.

InstallingthePCVlines–ifthisisan2014-2015therearetwolines,2016-currentusesasingleline.UsetheinstrucYonsforyouryearvehicle.

2014-2015yrs.:RemovethelinesbysqueezingthegrayconnecYons.Removebothlines,onefromthesumptankandtheotherfromthedriverssidevalvecover.2016-current:Removetheonesinglelinefromthesumptank.Sumpline:SqueezetheseblacktabstoreleasethelineInstallingtheVRPCVlinesandBarbs:Passengerside-UsingsuppliedPCVlineslidethishoseontothesumptankconnecYonandroutehosethroughthesamelocaYontabsasthefactoryhose.Usingsuppliedanglecutbarb,placethebarb50%insidethePCVhosewiththeanglecutendFacingoutwardasshown.OrientthebarbsothattheanglecutisfacingthethroMlebodyforacleanpullofvacuum.SimplypushintotheBLKsiliconhose.Thiswillnotcomeoutwhendrivingorduringroadracinguse.

InstallingtheVRPCVlinesandBarbs:Passengerside-UsingsuppliedPCVlineslidethishoseontothesumptankconnecYonandYghtenwithsmallclamp.RoutehosethroughthesamelocaYontabsasthefactoryhose.Usingsuppliedanglecutbarb,placethebarb50%insidethePCVhosewiththeanglecutendFacingoutwardasshown.OrientthebarbsothattheanglecutisfacingthethroMlebodyforacleanpullofvacuum.SimplypushintotheBLKsiliconhose.Thiswillnotcomeoutwhendrivingorduringracinguse.

Driverside2014-2015carsonly:Usingsuppliedanglereducerhose,shortPCVlineandanglecutbarbAssemblebyslidingthe3/8thshoseINTOtheanglereducerhose(noclampneededhere)nowplacethebarbintothe3/8thshosewiththeanglecutfacingthethroMlebodyforcleanpullofvacuum.

Re-installfrontfanshroudduct:

Install1.5inchtallsoZsealasshown:JustlineitupwiththecontourandbuMitupagainsttheVRunit Contour

Topviewofcompletedinstall

Driverssidepcv Passpcv

VRPCVhosetosumptankAllyearmodels

VRPCVHOSEtoValvecover2014-2015carsonly

Neopreneflowpad

Side/topviewofcompletedinstalla2onPrt2