Pop Charger

I ordered a pop charger, and am waiting for it to arrive. Has anyone had any problems with the install? The install instructions on Xterra Parts website aren't real clear.

It's not hard at all. Basicly, remove the whole airbox and replace it with the new intake. I don't know about the Air temp sensor location. I think it plugs into the back of the filter.

There isn't anywhere to plug the temp sensor on the new filter.

There's a plastic manifold that feeds the lower inlet to the stock air box...that's where the sensor is. Once the box was out, I just left the plastic piece there...sensor and all. The sensor is supposed to go near the inlet, and I figured it's close enough if you leave it in the original location.

That is why the pop charger isn't all that great! The K&N Aircharger has a shroud to prevent most of the heat from coming into the filter. The air temp sensor also plugs into the base of the air filter. The Pop charger only has a bracket, no shroud!

Thanks for the info. It should arrive in the next few days, hopefully no problems.

One of the first things I did when I got my pop charger on my Frontier was to fab a shield for it to keep out some of the heat from the motor. I also routed some piping to draw cooler air from outside. When I did the shield, I tapped a hole for the sensor placing it near the filter. Later on, I completed the project by making an intake tube. You can see pics of it all here and maybe you can figure something out that will work for you. www.picturetrail.com/ecujeb

Very nice job of building your own box! You didn't happen to make a cardboard copy of it? I think I might try and make one myself.

Thanks for the comments! No I didn't make a template for it... D'oh!

I just kinda winged it. I measured height and roughly width and kind of went from there. noting too precise... Who knows if it really made a difference or not. I would like to think it does offer some releif from the hot temps under there. If you do make your own, make sure you allow some extra for the tabs to mount it. That was the one area I was almost a little short in. If you get going and have some questions, let me know and I will try to help.

hey nozz, just curious, why did you choose popchrgr over airchrger? any difference? good luck w/install. i live right by Palms casino. ever wanna share good trail spots lemme know. Dafridge@webtv.net

AG's install looks awesome, I might need to try and fab something similar. 'fridge', I chose the Pop charger partly because of price and mostly because a lot of people seem to have run them for a while already without any problems. We should try to find more people in the Vegas area and get a local trail run together.

Regarding the temp sensor location on the POP...I just drilled a hole in the end of the filter and plugged it in. The truck seems to do better with air going across that sensor. I like the cold air box, I'll maybe give that a try next

hey good idea nozz! i know a few xterra owners. email me and i'll give you my number and any other info that you may need. lets do this. seriously!

Before I made the box, I stuck the sensor in one of the folds of the filter. The only pain was checking it every week or so to make sure it was staying put.

When I got my truck in March of '01, the pop charger was the only option. Since then there are a few more to pick from. The reason I ended up making the rest of the intake was the fact that I knew I wouldn't recover as much $$ by selling my pop charger. It wasn't all done at once, so as I added the different parts, I kept looking at ways to make it better. The only thing I do not like about my set up is that the intake tube being metal does attract a good deal of heat. I might have to look at making one out of something else or insulating it somehow... Maybe there will be a phase 4 of the project!

Ag, thanks for the reply! I guess I will break out the metal shears sometime soon and try and fabricate on similar to yours.

That is the nicest custom air intake i have seen yet... Great Job! I would love to have that on my new Supercharged X

Green with envy... :rolleyes:

Thanks! I have been pleased with it so far.