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Re: No Power above 3000 RPM [Re: Dryver] #953373 06/12/12 06:03 AM
Joined: Apr 2011
Posts: 326
Peabody Offline
Mudrunner
Yeah, I've been looking for parts to fab a hose. I can't find anything that will span the 7" run/3.5" rise with <10 degree offset. All of the elbows are too long and the 2.36" throttle body-side is an odd one to match. So I'm thinking about going your route and sealing it with tape. However, my hose is split so bad, I will need to insert some type of tube to support it. I wonder if I need to use CARB-compliant tape for this repair... Maybe then it will pass inspection?!? <img src="/forums/images/graemlins/shiner.gif" alt="" />


1997 Sportage 4x4, auto-trans, Warn manual hubs, 4" UPYOURKIA front lift, TJ 106AA rear springs, 2-5/8" body lift, 31x10.50 treads, SmittyBilt SRC front and XRC rear bumper, swing-out tire mount, OBX LSD front diff, Track Finder rear locker, 5.38 R&Ps and... really crappy gas mileage! <img src="/forums/images/graemlins/shiner.gif" alt="" />
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Re: No Power above 3000 RPM [Re: Peabody] #953374 06/12/12 11:15 AM
Joined: Dec 2008
Posts: 336
2002_Sporty Offline
Mudrunner
It would be a great write-up if you perform the Air Intake modification with measurments of the hose length, diameter and angle. I would appreciate it.


2002 4dr Kia Sportage 4X4
Tires:235/75/15, Wheels: Black 15x8 Steel ProComp 2.5" B.S., Hubs:Warn Manual, Lift:3" UPYOURKIA, Trailer Hitch, Cargo Rack, Clinometer.
Re: No Power above 3000 RPM [Re: Peabody] #953375 06/12/12 12:40 PM
Joined: Feb 2009
Posts: 146
Dryver Offline
Wheeler
2.36" is 60mm, which actually seems to be somewhat common. Don't know if it's CARB legal or not, but you could look into K&N part #85-6000, which is a 60mm x 900mm flexible air intake hose. The link didn't seem to want to work, so just do a web search on K&N 85-6000.


01 Convertible; Electric Fan; 3" Up Your Kia lift spacers; Tj 104's; 31x10.5x15's on Centerlines; Rear LSD.
GONE, all I have left are a few spare parts and the wheels.
Re: No Power above 3000 RPM [Re: Dryver] #953376 06/13/12 01:46 AM
Joined: Apr 2011
Posts: 326
Peabody Offline
Mudrunner
I will post the info on the intake hose as soon as I have a solution worked out. As mentioned, the throttle body-side of the hose is 2.36" (~60 mm). But the MAF-side is 2.75" (~70 mm). That's part of the problem I'm encountering: the dimensional-change in hose diameter. 2.75" intake parts are not too difficult to find. The smaller opening is odd, though I haven't looked at import parts spec'd to metric measurements.

On a related note, I was looking over exhaust pipe adapters and found some that could work for the application. But it wouldn't be easy to fab up a hose system that way. Then I started thinking that it might be possible to have a muffler-guy bend up some pipe and expand the openings so the outside diameters would match up with TB and MAF ports (or an adapter... like a 3", which is very common). If the bends are good, I could cut the pipe and install a hump hose coupler in the middle and attach the bends with reducers or straight couplers. The hump coupler will provide the flex for final fit and to compensate for engine torque. I will check with my muffler-dude soon to see if that approach is viable.

The other option is to cut out the corrugation on the stock hose and use the end pieces as couplers, either in conjunction with the above-mentioned approach, or using a section of solid tubing to connect the two ends. However, the solid tubing would not provide any flex. And I don't think the hose ends would, either.

And if none of that pans out, I can always use tape... <img src="/forums/images/graemlins/notooth.gif" alt="" />


1997 Sportage 4x4, auto-trans, Warn manual hubs, 4" UPYOURKIA front lift, TJ 106AA rear springs, 2-5/8" body lift, 31x10.50 treads, SmittyBilt SRC front and XRC rear bumper, swing-out tire mount, OBX LSD front diff, Track Finder rear locker, 5.38 R&Ps and... really crappy gas mileage! <img src="/forums/images/graemlins/shiner.gif" alt="" />
Re: No Power above 3000 RPM [Re: Peabody] #953377 06/13/12 03:20 AM
Joined: Feb 2009
Posts: 146
Dryver Offline
Wheeler
K&N adaptor kit #85-6003

"K&N's black rubber adapter hose allows an 60 mm connection to a K&N Apollo Universal Air Intake's standard 70 mm flange"


01 Convertible; Electric Fan; 3" Up Your Kia lift spacers; Tj 104's; 31x10.5x15's on Centerlines; Rear LSD.
GONE, all I have left are a few spare parts and the wheels.
Re: No Power above 3000 RPM [Re: Dryver] #953378 06/13/12 10:40 AM
Joined: Dec 2008
Posts: 336
2002_Sporty Offline
Mudrunner
Continued - Same thing.

K&N #85-6003
60mm to 70mm Flange Kit
$8.72 & Free Shipping
Site Here
[Linked Image]

70mm Hose Coupler
Length: 8.5" Roughly
$8.24 Free Shipping
web page
[Linked Image]



2002 4dr Kia Sportage 4X4
Tires:235/75/15, Wheels: Black 15x8 Steel ProComp 2.5" B.S., Hubs:Warn Manual, Lift:3" UPYOURKIA, Trailer Hitch, Cargo Rack, Clinometer.
Re: No Power above 3000 RPM [Re: 2002_Sporty] #953379 06/17/12 08:22 PM
Joined: Apr 2011
Posts: 326
Peabody Offline
Mudrunner
I was able to piece together a patch for the corrugated hose using a 2.5" coupling for exhaust pipe. The OD on it 2-5/8", which is about the same ID as the corrugated section of the hose. So I cut out the split sections of the hose and used the coupling to splice everything together. I had to rearrange the hose pieces to get everything to fit without straining, to include the MAF body. I'll post a pic soon so you get a better idea of the layout. But it did the job - the intake hose is sealed now and my Sporty runs like a champ again (no P0171 codes)! <img src="/forums/images/graemlins/kewl.gif" alt="" /> This patch-up is temporary. Now that I have found a good layout, I'm going to order some parts so it seals better and looks a little more "presentable". Yep, a good split in that hose can be a real headache... <img src="/forums/images/graemlins/lol.gif" alt="" />


1997 Sportage 4x4, auto-trans, Warn manual hubs, 4" UPYOURKIA front lift, TJ 106AA rear springs, 2-5/8" body lift, 31x10.50 treads, SmittyBilt SRC front and XRC rear bumper, swing-out tire mount, OBX LSD front diff, Track Finder rear locker, 5.38 R&Ps and... really crappy gas mileage! <img src="/forums/images/graemlins/shiner.gif" alt="" />
Re: No Power above 3000 RPM [Re: Peabody] #953380 07/21/12 07:19 AM
Joined: Apr 2011
Posts: 326
Peabody Offline
Mudrunner
OK - here's an easy fix for a split intake hose caused by a body lift stressing the old rubber. I found the simple solution, though not cheap, to use the following silicone hose componenets: 1 reducing coupler, 2 90 degree elbows and 1 stainless steel joiner. The reducer connects to the throttle body-side of the intake, with the joiner connecting the reducer to one elbow. The mass air flow sensor assembly goes between and connects the two elbows and the last elbow connects to the air cleaner. I had to trim about 1.25 inches of hose of each elbow on the side that mated with the MAF body. So the MAF body sits at a 45 degree angle now. But the need to trim is where you can compensate for variations in the body lift. And the silicone elbows provide more than enough pliability to provide a stress-free hose assembly. I tried using hump couplers instead of elbows. But they are far too stiff to make the bends needed to span the ~12" gap between air cleaner and intake tube. That said, the total cost was about $70 US, plus shipping. And a few $ more if you want the fancy T-bolt clamps (they are very nice and work well, if you want some under-hood bling <img src="/forums/images/graemlins/smile.gif" alt="" />). Yep, it costs more that the $40 Kia hose. But the Kia hose will eventually fail again. This setup will last. I will try to post a photo soon...

On another note, I was a total dipstick when I removed the throttle body while changing plugs and wires last year. When I re-installed the throttle body, I flipped the gasket that goes between the TB and the intake manifold. In retrospect, I know how it happened - I fiddling with the heater hoses that attach below the TB and dropped the gasket, then put it in backwards so the lower slot was not sealed. And that caused one more vacuum leak in the intake that was causing the P0171 error code... and it was the last vacuum leak to be found. Fortunately, it only took $12, a few hours and an extensive collection of self-degrading 4-letter words to dig myself out of that debacle (the $12 purchased 1 roll of rubberized gasket material - a lifetime supply, 2 feet of 5/16" hose and 3 small hose clamps... I bypassed the heater lines through the TB). Yep, that fixed the hissing sound coming from below the TB and my Sporty runs like a champ... at least until I work on it again. <img src="/forums/images/graemlins/shiner.gif" alt="" />

<img src="/forums/images/graemlins/kewl.gif" alt="" /> <img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/patriot.gif" alt="" />


1997 Sportage 4x4, auto-trans, Warn manual hubs, 4" UPYOURKIA front lift, TJ 106AA rear springs, 2-5/8" body lift, 31x10.50 treads, SmittyBilt SRC front and XRC rear bumper, swing-out tire mount, OBX LSD front diff, Track Finder rear locker, 5.38 R&Ps and... really crappy gas mileage! <img src="/forums/images/graemlins/shiner.gif" alt="" />
Page 3 of 3 1 2 3

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