Alias23 Lotus Exige V6 Air Intake Kit Install Guide

Alias23 · Installation Guide

Exige V6 Air Intake (V2)

Step-by-step fitting guidelines for the Alias23 performance intake kit — Lotus Exige V6, V6S & 350 Sport.

Alias23 Lotus Exige V6 Intake Kit - Available Here

Kit Contents

  • 1× Air filter element
  • 1× Main intake pipe
  • 1× P-clip (with M6 bolt & washer)
  • 2× M4 8mm bolts & washers (intake pipe)
  • 2× M4 10mm bolts & washers (V6S solenoid blanking)
  • 2× spare M4 washers — keep safe
  • 1× Jubilee clip

Tools You'll Need

  • 4mm Allen key (engine shrouds)
  • 8mm socket (intake hose clips)
  • 10mm socket (airbox base bolts)
  • Trim removal tool & Phillips screwdriver
  • Drill (to enlarge solenoid bracket for M6)
  • Cable ties & a clean cloth
  • MAF sensor cleaner (optional)
⚠ Important — Please Read Alias23 accepts no liability for any loss, damage or injury arising from installing or using a product we supply, or from any advice given. This is an aftermarket motorsport track part, sold without warranty, expressed or implied. Effectiveness, durability and reliability depend entirely on how the product is installed, used and maintained — the user assumes the risk. These instructions are guidelines only; professional installation should always be sought. Working on your car can be dangerous — if you are unsure, leave mechanical or safety-critical work to a skilled mechanic. Motorsport and driving can be dangerous, resulting in death or personal injury.
Step 01

Remove the engine cover shrouds

For extra room during installation, first remove the factory engine bay shrouds (outlined in red, Figure 1.0). This is done with a 4mm Allen key.

Tip: You may choose to leave the shrouds off the car at the end of the install to aid air circulation and shed a little weight.
Figure 1.0 — Engine bay. Shrouds outlined in red; flexible intake hose outlined in yellow.
Step 02

Remove the flexible intake hose

Remove the flexible intake hose (outlined in yellow, Figure 1.0) by loosening the two clips on either side using an 8mm socket. You may also wish to disconnect the oil breather hose, which sits on a retainer clip.

While the intake hose is off, it's a good moment to give the throttle body a quick wipe to clean.

Step 03

Remove the stock airbox — Part 1 (MAF & top half)

Unclip the MAF sensor — push in to unlock, then pull to remove. Unbolt/unscrew the MAF sensor, carefully pull it out, and set it somewhere safe until reassembly.

Optional: Spray the MAF with a specialist MAF cleaner and let it air-dry while you continue. Not essential, but a good idea while it's out.

Remove the top half of the airbox by unclipping the three silver latches. The top and right-hand latches usually release easily by hand. The left-hand latch can be tricky — it's part-hidden under the clam. If you can't reach it, don't worry; we'll release it in a later step.

Figure 2.0 — MAF sensor location (outlined in red).
Step 04

Get the car in the air

On level ground with the handbrake on, follow the Lotus handbook instructions for jacking the car. You'll need to access and remove the rear left wheel (airbox side).

Safety Always follow the official Lotus handbook procedure for jacking and supporting the vehicle.
Step 05

Remove the wheel arch trim

With the car safely raised, remove the rear left wheel. Then remove the wheel arch trim using a trim removal tool and Phillips screwdriver — there should be 6× trim screws plus one pull-out wheel arch stud.

With the trim removed (Figure 3.0) you'll see the side intake funnel (green line). Pop the corrugated ducting off by pushing it upwards after loosening or removing the zip ties.

Figure 3.0 — Side intake funnel (green line). Push the corrugated ducting upwards.
Step 06

Remove the stock airbox — Part 2 (the hidden latch)

Above the suspension turret (Figure 4.0) you'll now see the "hidden" latch mentioned in Step 03 — it's now visible and accessible. Unlatch and release it, then go back into the engine bay and lift out the top half of the OEM airbox.

Figure 4.0 — The "hidden" top-half airbox latch above the suspension turret (yellow).
Step 07

Remove the stock airbox — Part 3 (vacuum pipes)

With the top half removed, you'll have two vacuum pipes loose: one from the charger (red dots) and one connecting to the Y-piece (yellow dot) — see Figure 5.0.

  • Disconnect the red-dot pipe from the charger and remove it completely.
  • Disconnect the red vacuum pipe (this runs to the exhaust flap solenoid) from the Y-piece, then connect it to the charger — into the port you just freed up (Figure 6.0).
  • At this point you can also remove the black vacuum lines and the Y-piece originally connected to the airbox.
350 Sport 350 Sport owners: the plumbing is different — see Step 11 before disconnecting these pipes.
Figure 5.0 — Charger pipe (red dots) and Y-piece connection (yellow dot).
Figure 6.0 — Re-routing the vacuum pipe to the charger (traced in yellow).
Step 08

Remove the bottom half of the airbox

Use a 10mm socket to remove the three bolts holding the bottom half of the OEM airbox in place (Figure 7.0). The bottom half should now be loose.

You may be able to lift the OEM airbox out completely at this stage. If it feels caught, check underneath — one of the ducts may be wrapped around the wiring loom (highlighted in red, Figure 8.0).

If so, loosen the jubilee clip highlighted in yellow and pull the ducting off. You can then push the ducting under the red-highlighted wiring loom, freeing the airbox for removal.

Figure 7.0 — Bottom half of the OEM airbox; remove the three 10mm bolts.
Figure 8.0 — Wiring loom (red) and the jubilee clip to loosen (yellow).
Step 09

Assemble the Alias23 intake kit

First, wipe all the intake piping down — inside and out — with a clean cloth to remove any dust collected during packing and postage.

Connect the intake pipe to the air filter element using the supplied jubilee clip. Ensure a nice, air-tight seal: any crimping or uneven seal will cause "fluttering" noises as air gets trapped and expels. Make sure the seal is even all the way round — crimping can result from both over- and under-tightening.

Bolt the MAF sensor to the intake pipe using the supplied M4 8mm bolts & washers. Push the MAF evenly into the flange for a tight seal. To help the O-ring seat properly, tighten gradually and evenly between each bolt. Make sure the MAF is seated and sealed correctly.

Figure 9.0 — Assembled Alias23 intake pipe with filter element and MAF sensor.
Step 10

Fit the intake

With the OEM airbox removed you should have plenty of room. Install the new intake pipe into the OEM factory flex hose that connects to the throttle body — but don't tighten the clamps yet, just connect it up (Figure 10).

Use the supplied P-clip mounted to the back stay tube to support the intake pipe (Figure 11).

Ensure the air filter sits above the side air scoop and isn't fouling any other parts or the clam. You can check this by looking through the wheel arch to help with positioning (Figure 12).

Once you're happy with positioning, go back and tighten the factory flex-hose clamp and the P-clip so everything is secure. Re-connect the MAF wiring with no tension, and check there are no kinks in the crankcase breather hose.

Figure 10 — Intake pipe connected to the OEM factory flex hose.
Figure 11 — P-clip supporting the intake pipe.
Figure 12 — Filter positioned above the side air scoop (viewed through the wheel arch).
Step 11

Reposition the vacuum solenoid

Unbolt the solenoid that operates the flap in the stock airbox — it's simply bolted to the OEM airbox.

Exige V6S V6S owners: take the supplied M4 10mm bolts and M4 washers and block off the two remaining pipes attached to the solenoid (Figure 13).
350 Sport 350 Sport owners: the solenoid controls both the airbox and exhaust flap. On this variant, connect the red hoses to the solenoid — one from the exhaust, the other into the charger (short length). See Figure 14.
Don't disconnect the solenoid: it must remain connected, or you may get an error code on the dash as the ECU believes there's a missing actuator.

Solenoid fixing: the hole on the solenoid bracket needs drilling out to enlarge it for an M6 bolt. Once enlarged, use the M6 button-head bolt (shown in the picture) to bolt the solenoid to the bracket, holding the P-clip for the black charcoal hose. Ensure the solenoid doesn't catch any piping as you angle and tighten it into place (Figure 15).

Figure 13 — V6S: pipes to blank off (red).
Figure 14350 Sport: red hose routing to the solenoid. 350 ONLY
Figure 15 — Solenoid fixing point (green circle).
Step 12

Final stage & reassembly

The intake is installed. Now refit the engine shrouds if you wish — we left ours off to aid cooling and lose a little weight.

  • Ensure everything is tight, with no kinks or tension.
  • Tidy up any loose wiring and piping with cable ties.
  • Reinstall the left-hand wheel arch trim (a few spare arch screws are included).
  • Refit the wheel and torque to factory settings.
★ Important final note — ECU re-learn Your ECU needs the chance to re-learn. Let the engine run at idle for at least 10 minutes after installation so it can start to adjust to the new airflow. After that, treat the car as though it's being run in for the next 20 miles — gradually build momentum and revs to let the ECU re-learn smoothly.

If you skip this you'll get an error message on the dash. Give the car time to learn — don't install and then go full throttle out of the driveway! Enjoy.
Alias23 · Exige V6 Air Intake (V2) Installation Guide · alias23.com

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