Chevrolet Silverado Intake Install - Heavy Metal!

The quest for more power, louder noises, and a sweet look under the hood is a never-ending battle. While Chevrolet's '99-'03 Silverado provides ample punch and a subtle growl when jamming the loud pedal, more power is always well received. Whether you're towing a trailer, blasting the 1320, or just passing slower traffic on the highway, we could all use some extra ponies.

For years, K&N has been showing us filters that offer our trucks extra protection, and because they're washable, it could be the last filter you have to buy, which saves money in the long run. With that said, the real appeal of K&N products has been the performance gain. Whether you are accustomed to getting 5 to 35 horsepower, freeing up your truck's intake has always meant better performance.

According to K&N engineers, the company's intake kits really don't create horsepower as much as they free it up. By improving the flow of the intake path, offering a larger orifice for the air to travel through, and by using a more efficient, less restrictive air filter, the engine simply gets more air.

While we're sure you've seen previous stories in the pages of Sport Truck on K&N's FIPK (Fuel Injection Performance Kit), the Series-77 is a little different. Unlike the FIPKs, which are made out of roto-molded polyethylene, the Series-77 is constructed out of mandrel-bent aluminum, which is either polished to a high shine or powdercoated gunmetal gray. You will get all of the same performance from the 77 as you would from a traditional intake kit, but you will also get some flash when you open the hood.

Start to finish, the installation took about an hour, including a slight refuel at the local Burger King, and required a flat-tip screwdriver, a ratchet, a 10mm socket, and a 4mm Allen wrench. A little dyno-testing at the K&N facility in Riverside, California, showed 8 more horsepower at the wheels, which is not too bad for a little bit of wrench time and 260 bucks.

What's In The Box? The K&N...        read full caption What's In The Box? The K&N Series-77 intake system comes with all the clamps and hardware necessary to install the nice shiny mandrel-bent intake. Shown in the photo are the tools needed for the job. Sorry, but you'll have to provide those yourself.	1. Per the instructions from...        read full caption 1. Per the instructions from K&N, we began by removing the plug connected to the MAF sensor. There is a little tab that you will need to depress to disconnect the plug.	2. Next, the OE hose clamps...        read full caption 2. Next, the OE hose clamps that hold the MAF were loosened to remove the sensor. Be sure to handle the MAF gently, since it is a sensitive piece of electronics and must be reused.
3. Removing the hose clamp...        read full caption 3. Removing the hose clamp and main intake duct to the throttle body was the next order of business.	4. With everything loose,...        read full caption 4. With everything loose, we removed the stock intake tube and airbox assembly. The airbox snaps into some grommets on the bottom, so you might have to tug on it a little bit to get it out.	5. There are two bolts that...        read full caption 5. There are two bolts that are hiding under the airbox that need to be removed and replaced with the K&N rubber isolated studs.
6. There is a little preassembly...        read full caption 6. There is a little preassembly that needs to be done before the new intake can be put in the truck. The MAF needs to be installed into the heat shield; K&N provides all of the hardware and gaskets needed for this task. Take note of the directional airflow arrow on the MAF and make sure it points toward the throttle body.	7. The last little bit of...        read full caption 7. The last little bit of assembly is installing the rubber gasket around the perimeter of the heat shield. This will ensure a good seal against the Silverado's hood and keep most of the heat from the motor away from the filter-and less heat means more power.	8. With the heat shield assembled...        read full caption 8. With the heat shield assembled and the MAF installed, we secured the heat shield to the rubber-mounted studs and loosely dropped the locknuts in place. Don't tighten anything just yet, because you'll want to get everything installed and adjusted before tightening it in place.