My inclination with my X would be to do the following in this order: (1) custom Y-pipe and less restrictive exhaust; (2) less restrictive air filter in modified stock airbox (rather than CAI); and potentially (3) intake manifold spacer.
Unlike my previous offroad rigs, that had substantial high performance engine modifications (pre-OBD2), this one is my daily driver/primary transportation. I want to keep the engine close to stock because in the event of a problem far from home, I need to be able to take my X to any dealer or independent mechanic and not be turned away because they aren't comfortable working on a modified engine.
My questions, to those who have done the mods listed above, are these:
A) Does one need an electronic "tuner" with only mods 1 and 2? (I suspect not)
No.
B) Are there any intake manifold spacers that are "CARB" approved? (If not, who in California has one and what issues, if any, with the smog nazis?)
No, there are no carb approved IMS. There are CARB approved CAIs (K&N has one). The IMS products that are available are from 2 small vendors. XTP makes an alliminum one (I had a good experience with him, but he was the only vendor at the time) - there's another one now made by CXJ that's Phenolic. I believe both are comparible in performance. Really its the quality of gasket you need to look out for. Also I can't speak for alluminum vs. phenolic.
C) Is there any benefit to mod 3 (intake manifold spacer) without a custom tune?
Yes. Improved throttle response / lower torque curve. There are a few reviews on the XTP Group by thread.
D) Does mod 3 (intake manifold spacer) create problems (i.e., reduction in performance or mileage) without a custom tune?
None that I know of.
E) Which tuner and who sells it?
No sure what you're asking here? There are 3 standard tuners that come to mind. SuperChips (they do not have tunes for 2011+ Xterra's though), BullyDog, and HyperTech. They are all pretty similar, with BullyDog having the ability to act as a realtime monitor if you keep it plugged in.
UpRev is a custom tuning solution. I had a superchips, but after I modded beyond its capabilities I sold it for enough coin to justify (in my head) going to UpRev. UpRev also comes with advanced Nissan diagnositic software. (In other words it can read Nissan specific BCM codes, not just universal check engine codes.)
And lastly
F) Which tuners (if any) are capable of advancing the timing 2 degrees, or is this something only dealer equipment can do?
Unsure. I believe all of them are. I know UpRev can, and I think my SuperChips did, but I just ran the standard tune on that one.
Thanks. (I know I've asked a lot of questions.)