How to: Install OTRCAI VY LS1

[firebug]

Dug this up and added it to the How to's

This install refers to a PT (or copy) OTRCAI onto a VY1SS, although most steps should apply to other models. Feel free to point out differences if they apply?

Firstly I took a pic of the unmodded engine bay for no apparent reason.

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1179.jpg

After removing the turtle and radiator covers, unclip the MAF sensor harness and remove the MAF and MAF pipe by undoing the clamps and gently wriggle free from the throttle body and air box.

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1185.jpg

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1186.jpg

The radiator/condenser cover is held in place by a clip that slips into the plastic bracket on top of the radiator. This bracket will rub on the underside of the OTR so some will need to be removed. I trimmed about 7mm back diagonally as shown below. This will allow you to clip the radiator cover on again later if you decide to remove the OTR. This pic shows the MAF pipe still on. It was a progressive install and I still needed to drive it to get the MAFless tune done.

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1183.jpg

There is a wiring harness that runs along the top of the fan shroud for the thermo fans. The harness connector needs to be removed from its mount and relocated a little further down out of the way. Take up any slack in the harness by feeding a little down towards the LH fan motor. I zip tied the harness to the throttle body heater hose to ensure it didn?t move. While you?re at it, zip tie the MAF sensor harness somewhere safe.

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1187.jpg

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1188.jpg

[firebug]

Now you can fit up the OTR. I was told that a better fit is gained by bending the AC condenser back at the top towards the radiator. I was a little hesitant of this at first, but if you carefully massage it back using only your hands it will go back quite easily without damaging it. I also rubbed the front edge with some fine emery paper just to take the sharp edge off.

While you are fitting the OTR and moving it around a little to get it just right, you may damage the rubber seal on the throttle body. To prevent this, wipe a little Vaseline around the inside of the rubber before fitting. If the clamp is over tightened, the OTR may crack due to engine movement. Only tighten clamp so that OTR is firm on throttle body but still allows a little movement.

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1215.jpg

The OTR I bought came with a rubber grommet already fitted for the IAT sensor to fit into. Remove IAT sensor from your old MAF pipe and install into OTR. And there you have it, all ready for a MAFless tune.

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1210.jpg

For those of us who are not happy with the bare look of the now exposed radiator and condenser, the stock cover can be refitted. Similar pictures of this have been posted here before, So credit goes to those who did it earlier, thanx guys? This is how I went about it.

Remove the OTR from the throttle body and fit radiator shroud in its original position. Place OTR on top, centred and as close as you think it would be when fitted. Carefully trace around the OTR using a texta. You may need someone to hold the OTR in position while you trace. Allow an 8mm at least outside this line for moulding and clearance of OTR. Remove shroud and carefully cut out using a Dremel tool (or similar) or a jigsaw with a fine cutting blade. A little masking tape near your cutting line will help prevent the tool from marking the plastic. Refit OTR and check that the cut is correct, trim as is needed.

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1211.jpg

Purchase some ?Pinch Mould? to line the inside of the cut. I went to ?Clark Rubber? and got 1 metre. Cost around $8. I took the shroud with me to pick the right size.
Starting at one end, press the mould onto the shroud edge making sure you get it tight into the corners. Trim the other end using a knife between the metal inserts.

http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1214.jpg

Fit to car, drink beer and admire? :beer:
http://i105.photobucket.com/albums/m231/Firebug_01/DSCF1218.jpg

That is how I did it anyway. Hope it helps anyone who?s not sure how to go about it?

Cheers... :)

[BOMI]

Looks good man :thumbs:

Thanks for the write up.

Just a point to note, I think cars will run rich with no MAF untill they get a MAFless tune. Mine made less power when I had the MAF in backwards :lmao: Doh!! :eek:

I could be wrong but yeah, runs rich, FYI :)

Troy :cheers:

[SSUte01]

Looks good man :thumbs:

Thanks for the write up.

Just a point to note, I think cars will run rich with no MAF untill they get a MAFless tune. Mine made less power when I had the MAF in backwards :lmao: Doh!! :eek:

I could be wrong but yeah, runs rich, FYI :)

Troy :cheers:

Fair point Troy about the tune to suit the mods.

Bill's right, Sonny sorted him right out :yep:

BTW - Nice write up, for all those wondering looks tops in the flesh too, Bill did a very tidy job overall

[DaveHAT]

Nice one Bill, great effort on these "how to's" that you've been doing for TC.

Much appreciated ... :beer:

FYI, a MAF tuned car will most likely not run with the MAF meter missing, disconnected or otherwise. If it does run at all it will be like trying to drive a busted arse with 2 extra holes. :yep:

[Delft Maloo]

nice neat job and a good write up too.

[35R]

excellent post and great job

[firebug]

Thanx guys. :cheers:

I posted this originally at LS1.com. I encourage how to threads and love reading them, no matter what sort of car it's about. Creating my own was alot of fun. Might have another one coming soon... :headbang:

[Pulse Red]

Thanks for posting this, I may need it soon! Very good How To guide.

[VYss Kiwi]

Another thing to do is bypass the hot water hose that runs under the throttle body,This only adds heat to the cold air passing through the body.Simply take off on left side and run the right side back to raidiator,takes about 5 min.:yep: :beer: