How's this for annoying...

Used the install tips for the Vararam posted on this forum. All went reasonably well, with one caveat:

If you cut the shroud in place (no removal from vehicle), finish your cut at the bottom of the shroud, not at the top.

While cutting the shroud, I started at the bottom and finished at the top. As the plastic broke loose, I lost balance causing my box cutter knife to nick the A/C condensor.

Very shortly thereafter, a strange hissing sound began as the refrigerant started leaking from the punctured condensor.

I don't know what the tubing in the condensor is made of, but it's not very tough. Between the condensor and labor to install, I figure the Vararam (and my clumsiness) will have cost about $1000.00.

 

Should have searched before doing the mod(I didn't either). I cut mine as well. The dealership actually sent mine to a shop and had it repaired. Made it a lot cheaper.

 

 

Ouch!

Don't feel too bad though, there have been several members do this.

 

look on the bright side. the car will be faster then most now its lighter than others with the VR. and now your engine wont be as hot with the air on

 

That really Sucks.

 

Gonna have to make note of this! Damn.

 

Shockerracing.com - C6 CORVETTE VARARAM INTAKE & THROTTLE BODY SPACER INSTALL

Tools Needed:

Razor Knife
Flathead Screwdriver
Size 4 and Size 5 Allen wrenches
Pliers
White Marker or Crayon
Scotch Tape
10mm Socket and Ratchet

Step 1: First you will need to remove the stock air box assembly. In order to do this unclip the two metal clips on each side of the stock air box and pull the 2 stock air filters up and out. Then there is the long plastic cover that goes over and across both filters, this just pulled up and off once the two factory filters were removed. Then unplug the Mass Air Flow sensor connector, there is a light gray safety piece that has to be pulled out of the plug so that you can unplug this connector. Then unplug the other sensor from the air bridge between the MAF and the Throttle Body. Next, using the flathead screwdriver you will need to loosen the hose clamp that holds the air bridge onto the throttle body. Once that is loose you can pull the bridge off of the throttle body and pull the whole assembly up and off(note; there are two plastic plugs that hold the factory airbox down these unplug just by pulling them up and off).

Step 2: Installing the Throttle Body Spacer: in order to remove the throttle body spacer you will need to remove all 4 of the 10mm bolts that hold the throttle body to the intake manifold. These unscrew pretty easily and will allow enough room for the spacer to slide behind. Using the new bolts that have been provided with the spacer(they are longer), slide the bolts through the throttle body and through the spacer and screw them back into the manifold. You will want to tighten these until they are snug but do not overtighten as the rubber with then become smashed. You will want to come back and tighten these up again after the intake is completely installed and you let the engine run and warm up a bit.
a.

b.


Step 3: Next you will want to assemble the whole intake just so that you know what the whole intake will look like. You can attach the MAF to the intake using the provided adapter (red) and using the two clamps. Then this will all be ready to go after you cut the hole in the radiator shroud.
c.


Step 4: (NOTE: Many people have accidentally damaged their radiator when cutting the shroud. I highly recommend sliding something up behind the shroud such as some thick cardboard to protect your radiator)Next you will need to cut out the template for cutting the radiator shroud. Then you will to lay the template out on the radiator shroud and center it. You can see in the next picture how I traced the template. Then the next two pics show how it looked after I initially cut the shroud. I then found after trying to put the intake in that you need to cut further down on the shroud to allow the intake to sit properly. The two plastic humps at the bottom need to be almost completely cut off in order for the intake to sit flush and mount properly. We took our time and kept cutting small amounts off at a time to be sure not to cut off more than was necessary. Once you cut enough and test fit the intake so that is sits properly you can install the rubber gasket piece that surrounds the edge of the shroud where you just cut. This gasket gives the radiator shroud a nice clean look.
d.

e.

f.


Step 5: Next you will need to remove the two allen screws that are in the front of the radiator shroud. The stock allen screws were a size 4. Then you can use the new allen (Size 5) screws that are provided to screw in the red bracket. Once the bracket is mounted be sure to check that the bottom part of the intake hooks on the two plastic bumper tabs so that it looks like picture g. Once this is all set you can slide the bridge back over the throttle body and tighten down all of the screws for the clamps. Double check all of your screws and bolts to be sure they are tight.

g.


Here are some pics of the finished product:




Once everything was installed and checked start her up and let her run a bit so that the Throttle body spacer gets warm and resnug the throttle body bolts.

Vararams instructions are pretty good but I just felt that some things would have gone a little more smoothly if they had been mentioned so that is why I did my own write up.

 

Condensor is $240 from Chevrolet. Don't ask me how I know this.

 

did the same thing, glad its winter.

 

Shocker, thanks for the timely info! I got my headers and vararam from one forum member today, and should get my spacer and (extra) shroud from another forum member tomorrow. Kevin

 

No problem Ginny, I wish more people would see this write up! I keep trying to post it, because so many people have damaged their Condensors!

 

It will be our secret....

 

One thing that was really a pain for me was trying to get the all of the intake paraphenalia to line up. The "accordion" was particularly difficult to compress and I did not even use the TB spacer.

Does anyone make a replacement piece for the "accordian" that would reduce the congestion and make a smooth transition from the Vararam to the TB?

 

Is there a template I could use to cut the spare shroud, and then swap? Kevin

 

A template comes with the intake. However, if you purchased it used, send me a pm with your address and I'll send you mine.

 

It took longer to remove and install the precut shroud than just cutting the shroud in place. Next one gets cut in place.

 

I put my VaraRam on last weekend. I printed out Shocker's
instructions and used it to do the install. Works perfect, just
take your time when cutting the shroud. Thanks Shocker for
your great detailed instructions. Better than the instructions
that comes with it.
What a wealth of info on this forum!

 

This is like the 3rd one i have seen on the forum
Just not worth trying to cut in the car !

 

I have read a ton that a ton of people have damaged the condensor, but if you would just slide something up behind your shroud before you cut it you will protect yourself from slipping and damaging it. It would only take a couple seconds to slide a thick piece of cardboard up there.