1 of 8 Installing a 2001-2004 Halltech Stinger Air Intake System into

Installing a 2001-2004 Halltech Stinger Air Intake System into a C5
Dave68
Tools required:
• Large flat-blade screwdriver
• Small flat-blade screwdriver
• Some masking or Duct tape
• A bit of patience
MAF-end
Warhead filter
Airbridge
Rubber transition hose: attaches to
throttle body
Hole to mount elbow for rubber hose
1. Completely remove your stock airbox assembly. Note: You must pop the stock airbox
away from the two retaining pins. This is done by standing in front of your C5 and
with hood open, reaching down behind the airbox and pushing it toward the engine.
You will see the one pin on each side – push as close to the pins as possible. You will
hear a popping noise when the pin disengages from the airbox. Refer to step F for
additional tips.
a) Remove the gray security clip from the MAF connector with a small
screwdriver. You must press down on the small, raised part of the clip before
pulling it off the connector. See figures 1 and 2.
Security clip
Figure 1: Pulling MAF security clip
Figure 2: Pulling off the MAF connector
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Installing the 2001-2004 Halltech Stinger Air Intake System into a C5 (continued)
b) Remove the connector by pressing down on its center and then pulling it off.
Tape the connector to the radiator shroud so that it is up and out of the way.
c) Pull off the rubber hose that is connected to a 90 degree elbow in the airbox.
To loosen the plastic hose clamp, push its upper toothed section away from
the lower toothed section so that the meshed teeth are separated from each
other. Either tape the clamp to the hose or remove it entirely, so as not to
allow it to drop down into the airbox. (…been there, done that!) See figure 3.
Figure 3: Hose connection
d) Loosen the 8mm hose clamp that holds the accordion bellows to the throttle
body.
e) Pop-off the airbridge retainer from the rubber grommets at each side of the
OEM airbridge. See figure 4.
Figure 4: Airbridge retainer
f) Remove the air filter and its frame from the airbox. This will allow you to see
the grommets that are keeping the airbox attached to the front part of the car.
See figure 5.
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Installing the 2001-2004 Halltech Stinger Air Intake System into a C5 (continued)
Left side airbox
retainer grommet
Figure 5: Airbox retainer grommet
g) Now that you can see the attachment points, reach down near one of the
grommets and pull the front of the airbox toward the engine. Watch the
retaining pin slip through the grommet. Now repeat for the other side’s
grommet.
h) Pull the accordion bellows away from the throttle body amd remove the OEM
airbox and bridge assembly. You’re halfway there!
2. Remove the airbox hose end and the airbridge end from the MAF sensor by first
loosening the band clamps and then twisting and pulling. The airbox end will slip out
rather easily, but the airbridge end may take a bit of muscle to disconnect. See figures
6 and 7.
Figure 6: Airbox end of MAF
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Installing the 2001-2004 Halltech Stinger Air Intake System into a C5 (continued)
Figure 7: Airbridge end of MAF
3. Install the Halltech airbridge MAF end onto the MAF and tighten the clamp. Jim Hall
recommends using a bit of Windex to make it easier to make this connection.
Note: The rubber seal that allows the Halltech airbridge to seal against the MAF
(Mass Air Flow) sensor, must be installed correctly. Take a look at figure 8. You will
see an inner and outer lip.
Outer lip
Inner lip
Figure 8: Airbridge to MAF seal
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Installing the 2001-2004 Halltech Stinger Air Intake System into a C5 (continued)
The end of the Halltech airbridge must fit in between the two lips. See figure 9. Also,
make sure the seal protrusions are positioned correctly through the cutouts in the band
Protrusion through
band clamp
clamp.
Figure 9: Seal/Band clamp assembly
4. Press the MAF sensor into the airbridge. You may have to wiggle the MAF sensor to
get it to seat properly. See figure 10.
Figure 10: MAF-to-airbridge assembly
Before tightening the clamp, rotate the MAF not only so that its body tabs align with
the cutouts in the rubber seal, but also so that the MAF connector receptacle (built
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Installing the 2001-2004 Halltech Stinger Air Intake System into a C5 (continued)
into the MAF body) is oriented correctly. See figure 11.
Position MAF
connector as shown
Figure 11: Correct orientation of MAF
5. Remove the elbow from the OEM airbox and leave the airbox rubber grommet in
place. You will not need this in the Warhead filter. Insert the elbow into the Warhead
filter hole.
6. Remove the Rubber “transition” hose (smooth TB coupler) from the end of the
Halltech airbridge and install it onto the throttle body. You may also install the it on
the airbridge, first. You’ll have to loosen the transition hose’s clamp considerably
first. After assembly, tighten the clamp.
7. Install the Halltech airbridge/MAF assembly onto the transition hose by first rotating
the airbridge assembly clockwise (as you are facing the front of the car from near the
driver-side door) and then pushing/rotating it into the transition hose. I had a hard
time until I tried this position. Pay close attention to the lower part of the transition
hose to ensure that it is not pinched inside the airbridge. Once you get the airbridge
started into the transition hose, you can then rotate it back to its proper position.
8. Now you can attach the Warhead filter onto the metal end of the MAF. Note: It just
barely fits down in there, but it DOES fit. I tightened the clamp through the hood
opening. See figures 12 and 13.
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Installing the 2001-2004 Halltech Stinger Air Intake System into a C5 (continued)
Figures 12 and 13 : Transition coupling and tightening Warhead clamp
9. Slip the teeth-mesh retaining clip onto the filter hose and install the rubber hose onto
the 90 degree elbow in the Warhead filter. Install the MAF connector and security
tab.
10. Check all connections. See figure 14. Remove any tools from the engine bay, close
the hood and take er for a ride! Note from Jim Hall:
Allow 25 miles of driving to provide relearn time for the PCM> All fuel trims will eventually retrim to
14.7:1 except WOT. That will be leaner, but still well within the power range and will likely provide 5 to
6% more torque and horsepower throughout the rev band.
Please understand that new air will not cause your car to run lean. The factory air fuel ratio is 12.3:1
for Wide Open Throttle, which is way too fat for max power. Our intake does not need programming
to operate properly, but will see added benefits from a good LS1 Edit program.
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Installing the 2001-2004 Halltech Stinger Air Intake System into a C5 (continued)
Throttle body
Figure 14: All done!
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