Callaway Honker question?
Thread Starter
Le Mans Master
Joined: Jun 2002
Posts: 9,220
Likes: 17
From: San Diego California
Callaway Honker question?
I was installing a Callaway Honker CAI today on my 2004 C5 LS1. When I noticed that the elbow between the MAF and the throttle body didn't fit, on the MAF. Then I noticed a hole in the side of the elbow. This I found surprising since I didn't have a hole on the stock ducts that I had just removed. I would assume this is pretty good evidence I was sent the wrong CAI for the year of my car. 
Since originally coming across this problem I have verified that P/N for 2001 - 2004 LS1s is 203.50.2500. Well the UPS contents discription is 203.51.2500 which is the Callaway 97 - 2000 P/N. I even went to my office were I left the installation directions. I just verified that they are infact for P/N 203.51.2500. Guess I was sent the wrong unit.
I have checked the vendor's website. My order does say 2001 -2004. So I didn't order the wrong one by mistake. I've already left them a message.
Thanks for letting me vent.
Since originally coming across this problem I have verified that P/N for 2001 - 2004 LS1s is 203.50.2500. Well the UPS contents discription is 203.51.2500 which is the Callaway 97 - 2000 P/N. I even went to my office were I left the installation directions. I just verified that they are infact for P/N 203.51.2500. Guess I was sent the wrong unit.
I have checked the vendor's website. My order does say 2001 -2004. So I didn't order the wrong one by mistake. I've already left them a message.
Thanks for letting me vent.
Last edited by SDLS1Rider; Jul 4, 2008 at 07:15 PM.
Team Owner
Joined: Mar 1999
Posts: 22,025
Likes: 192
From: At the beach in little Rhody
Whoops, cross country error too!!!
Call them Monday, if the cutout is the same you could get that done in the meantime, that is the most time consuming part of the installation anyhow. Also, Dave from Callaway is on this board, see if he will respond to a PM.
Call them Monday, if the cutout is the same you could get that done in the meantime, that is the most time consuming part of the installation anyhow. Also, Dave from Callaway is on this board, see if he will respond to a PM.
Team Owner
Joined: May 2001
Posts: 36,164
Likes: 2,511
From: ...tearing up the highways, one state at a time™®©
It sounds though as if it may have been bought from a third party dealer from the OP's statement. I agree with the idea of trimming for the base if possible however, the vendor would probably want the entire unit back.
Team Owner
Joined: Mar 1999
Posts: 22,025
Likes: 192
From: At the beach in little Rhody
Yep, me bad.
Thread Starter
Le Mans Master
Joined: Jun 2002
Posts: 9,220
Likes: 17
From: San Diego California
Yeah I got it from a third party vendor. I don't want to mention them until they get a chance to respond. I was pretty upset earlier. Didn't look good infront of the girl friend. It's suppose to be a holiday, and I was hopping to have it done before she arrived.
BTW, what do people use to cut the shroud. I was going to use a hacksaw?
How many bolts to remove the radiator shroud also. The instructions wasn't clear. The five bolts near the bottom front facia are obvious.
BTW, what do people use to cut the shroud. I was going to use a hacksaw?
How many bolts to remove the radiator shroud also. The instructions wasn't clear. The five bolts near the bottom front facia are obvious.
Last edited by SDLS1Rider; Jul 5, 2008 at 02:13 AM.
Le Mans Master
Joined: May 2005
Posts: 6,366
Likes: 249
From: Fort Lauderdale, Florida
Yeah I got it from a third party vendor. I don't want to mention them until tehy get a chance to respond. I was pretty upset earlier. Din't look good infront of the girl friend. IT's suppose to be a holiday, and I was hopping to have it done before she arrived.
BTW, what do people use to cut the shroud. I was going to use a hacksaw?
How many bolts to remove the radiator shroud also. The instructions wasn't clear. The five bolts near the bottom front facia are obvious.
BTW, what do people use to cut the shroud. I was going to use a hacksaw?
How many bolts to remove the radiator shroud also. The instructions wasn't clear. The five bolts near the bottom front facia are obvious.
Team Owner
Joined: Mar 1999
Posts: 22,025
Likes: 192
From: At the beach in little Rhody
And you need to remove the plug for the hood light that is attached to the shroud. I am now wondering if you can cut it as if I remember correctly you attach the Honker to the TB then mark the shroud with tape. Since you can't attach it you may not be able to do any of the cutting.
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Burning Brakes
Joined: Mar 2003
Posts: 1,156
Likes: 2
From: Arlington VA
You are going to need to first install the unit without the shroud cutout and mark the shroud with some painters tape and a pencil. I used a small jig saw to cut the opening in the shroud after drilling the 1/2" holes in each corner according to the instructions. I then cleaned up the cut and the corners with my Dremel and a sanding bit. You need to follow the Callaway instruction to the letter. This unit fits very tight. When installing it on the car for the final time, leave all the fastners on the shroud loose until you get the unit hooked to the TB and base fastened down. Then go back and tighten all the shroud fasteners.I feel your pain on the issue with your vendor. After waiting close to 3 months for my Honker kit purchased from a 3rd party vendor, the one I received had a small scratch in the cover. I contacted the vendor and Callaway. Mike V at Callaway shipped me a new cover.
This is a great CAI kit with superior build quality. You might want to check out Elite Engineering and purchase one of their radiator screens. I have one on my car and this does an excellent job of keeping the debri from getting sucked up into the filter area of the Honker. Good luck with your installation.
Thread Starter
Le Mans Master
Joined: Jun 2002
Posts: 9,220
Likes: 17
From: San Diego California
Not surprisingly, nobody answered the phone at the vendors. It's 4th of July weekend. Hopefully I'll hear from them Monday.
Nothing like working on your own car. I didn't realize the intake opening to the filter was so small! The CAI will be a great improvement.
Pro
Joined: Mar 2007
Posts: 600
Likes: 11
From: Wilmington NC
I used an air powered plastic saw to cut the shroud. The install is cake. You will need a rivet gun.
I noticed a huge improvement in my car after this intake. My 1/4 times went down and speed went up. It also makes the exhaust sound nicer.
You will get a kick out of the suction sound it makes underneith the car when you tap the throttle.
I noticed a huge improvement in my car after this intake. My 1/4 times went down and speed went up. It also makes the exhaust sound nicer.
You will get a kick out of the suction sound it makes underneith the car when you tap the throttle.
Thread Starter
Le Mans Master
Joined: Jun 2002
Posts: 9,220
Likes: 17
From: San Diego California
Anything is possible. But the directions tell you to remove the shroud. There isn't much room to cut a hole in the shroud with it installed. I would beleive that removing it is by far the lesser of two evils.
