Zeuslotion86
11-17-2007, 07:54 PM
Before i got my air intake, i searched the internet looking for any help on how to install this thing. I thought that i would contribute and add a step-by-step guide on how i install my Air Intake. It may seem long, but its quite easy, i was surprised. I tried to be as detailed as i could.
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Items:
Air Intake
Flat head screwdriver
Ratchet and i believe a #10 socket.
Saw used to cut plastic/rubber
I purchased the Air Intake from Ebay for $35 total($15 for intake, $20 shipping). I didn't want to spend $200+ on an intake...
#1.) I removed the original intake as well as the filter box. You should only need to use the screwdriver to loosen a few clamps. The two biggest are the ones around the manifold and one around the sensor that attach them to the big hose. The other ones are side tubes that attach to the main tube. Dont forget to unplug the sensor wires and anything else attached to the intake system. There is also a tube for hot air coming into the filter box located towards the bottom rear of the system. Detach that from the filter box as well. Save all the claps!
http://www.dubnetworks.net/dubhost/d/748-1/stockvwintake.JPG
http://www.dubnetworks.net/dubhost/d/738-1/intakeremoved.JPG
#2.) Remove the air mass sensor from the filter box. This is attached to the filter box lid when you removed the filter box. It should come off by unscrewing 2 bolts with the ratchet. This is what the space where the sensor would be attached to. You can see the two bolts. Unless you live in a colder part of the world, you may want to keep the filter box intact and that hot air hose, minus the stock filter. You may have to cut a groove inside the filter for the Air Intake to fit. I live in Georgia, USA, so i kept the box out. Don't worry about the two little hoses attached to the filter box. One should be coming from the engine and the other should just be re-routed into the box. Ill explain later.
http://www.dubnetworks.net/dubhost/d/746-1/sensorremoved2.JPG
#3.) Now, depending on what Air Intake you purchased, you may not need to modify that original hose. Mine was generic, so i had to do some modification. I replaced the original hose back into the manifold to measure. I placed the new Air Intake in the spot where the original filter box was located and positioned it to where i felt that i could get some good air flow. I then cut the original hose to length and reattached the sensor. Notice that i cut the hose before the "valley" so i can get a wider diameter, but i don't think it would matter in the long run.
http://www.dubnetworks.net/dubhost/d/744-1/sensorinstalled3.JPG
#4.) I then used the rubber sleeves that came with the the Air Intake to attach it to the stock. The intake sleeves fit nicely and i couldn't feel any leaks. I clamped the sleeves down with the provided clamps as well, also using the original clamps if needed.
http://www.dubnetworks.net/dubhost/d/740-1/intakesleeves4.JPG
#5.) My cone for my filter was a little tricky to get on. It didn't come with any instructions but i connected it this way. Notice the clamp around the bottom of the cone. The rubber sleeve is shoved into the cone and the clamp makes it tight enough that it wont slip off without some force.
http://www.dubnetworks.net/dubhost/d/731-1/filterconnected5.JPG
#6.) I checked that all the hoses were clamped correctly and there wasn't anything too loose. This is my intake installed (http://picasaweb.google.com/Zeuslotion86/GolfProject/photo#5131826876280272402). The intake also came with 2 small hoses that i put to some use (http://picasaweb.google.com/Zeuslotion86/GolfProject/photo#5131826979359487570) on some holes that were not being used right now. Remember the two hoses attached to the filter box? I found a screw that was big enough to wedge the opening for the hose coming from the engine. You can see it plugged in this pic (http://picasaweb.google.com/Zeuslotion86/GolfProject/photo#5131826953589683778)(top of picture in my hand). This little hose controlled a little vacuum mechanism inside the original filter box. It controlled a flap that allowed warm air into the air intake to help with cold weather starts. Seeing as i was in Georgia, i didn't need this. That being said, i also routed that hose that was also attached to the bottom of the filter box to point below the engine towards the floor. Make sure nothing is touching moving parts of the engine and you should be done!
http://www.dubnetworks.net/dubhost/d/734-1/filterdone6.JPG
http://www.dubnetworks.net/dubhost/d/736-1/holes+blocked62.JPG
http://www.dubnetworks.net/dubhost/d/742-1/plugged63.JPG
What mine looks like completed. I noticed a pickup on acceleration and a deeper noise from my engine.:) I noticed i had a bigger gain with higher RPMs, like when on the highway.
http://www.dubnetworks.net/dubhost/d/750-1/vwintakedone7.JPG
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I hope this guide helped you. It was fun trying to figure out how to install the Air Intake that i purchased. I also bought a Front/Rear strut bar and would be happy to post another thread on how i installed that. If you haven't noticed, you can browse my photo album from the pictures that i have posted. Its still in the works, and i have more pictures that i need to upload.
What do you guys think of my Golf so far? Any comment would be appreciated!
http://picasaweb.google.com/Zeuslotion86/GolfProject/photo#5131826927819879986
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=========================
Items:
Air Intake
Flat head screwdriver
Ratchet and i believe a #10 socket.
Saw used to cut plastic/rubber
I purchased the Air Intake from Ebay for $35 total($15 for intake, $20 shipping). I didn't want to spend $200+ on an intake...
#1.) I removed the original intake as well as the filter box. You should only need to use the screwdriver to loosen a few clamps. The two biggest are the ones around the manifold and one around the sensor that attach them to the big hose. The other ones are side tubes that attach to the main tube. Dont forget to unplug the sensor wires and anything else attached to the intake system. There is also a tube for hot air coming into the filter box located towards the bottom rear of the system. Detach that from the filter box as well. Save all the claps!
http://www.dubnetworks.net/dubhost/d/748-1/stockvwintake.JPG
http://www.dubnetworks.net/dubhost/d/738-1/intakeremoved.JPG
#2.) Remove the air mass sensor from the filter box. This is attached to the filter box lid when you removed the filter box. It should come off by unscrewing 2 bolts with the ratchet. This is what the space where the sensor would be attached to. You can see the two bolts. Unless you live in a colder part of the world, you may want to keep the filter box intact and that hot air hose, minus the stock filter. You may have to cut a groove inside the filter for the Air Intake to fit. I live in Georgia, USA, so i kept the box out. Don't worry about the two little hoses attached to the filter box. One should be coming from the engine and the other should just be re-routed into the box. Ill explain later.
http://www.dubnetworks.net/dubhost/d/746-1/sensorremoved2.JPG
#3.) Now, depending on what Air Intake you purchased, you may not need to modify that original hose. Mine was generic, so i had to do some modification. I replaced the original hose back into the manifold to measure. I placed the new Air Intake in the spot where the original filter box was located and positioned it to where i felt that i could get some good air flow. I then cut the original hose to length and reattached the sensor. Notice that i cut the hose before the "valley" so i can get a wider diameter, but i don't think it would matter in the long run.
http://www.dubnetworks.net/dubhost/d/744-1/sensorinstalled3.JPG
#4.) I then used the rubber sleeves that came with the the Air Intake to attach it to the stock. The intake sleeves fit nicely and i couldn't feel any leaks. I clamped the sleeves down with the provided clamps as well, also using the original clamps if needed.
http://www.dubnetworks.net/dubhost/d/740-1/intakesleeves4.JPG
#5.) My cone for my filter was a little tricky to get on. It didn't come with any instructions but i connected it this way. Notice the clamp around the bottom of the cone. The rubber sleeve is shoved into the cone and the clamp makes it tight enough that it wont slip off without some force.
http://www.dubnetworks.net/dubhost/d/731-1/filterconnected5.JPG
#6.) I checked that all the hoses were clamped correctly and there wasn't anything too loose. This is my intake installed (http://picasaweb.google.com/Zeuslotion86/GolfProject/photo#5131826876280272402). The intake also came with 2 small hoses that i put to some use (http://picasaweb.google.com/Zeuslotion86/GolfProject/photo#5131826979359487570) on some holes that were not being used right now. Remember the two hoses attached to the filter box? I found a screw that was big enough to wedge the opening for the hose coming from the engine. You can see it plugged in this pic (http://picasaweb.google.com/Zeuslotion86/GolfProject/photo#5131826953589683778)(top of picture in my hand). This little hose controlled a little vacuum mechanism inside the original filter box. It controlled a flap that allowed warm air into the air intake to help with cold weather starts. Seeing as i was in Georgia, i didn't need this. That being said, i also routed that hose that was also attached to the bottom of the filter box to point below the engine towards the floor. Make sure nothing is touching moving parts of the engine and you should be done!
http://www.dubnetworks.net/dubhost/d/734-1/filterdone6.JPG
http://www.dubnetworks.net/dubhost/d/736-1/holes+blocked62.JPG
http://www.dubnetworks.net/dubhost/d/742-1/plugged63.JPG
What mine looks like completed. I noticed a pickup on acceleration and a deeper noise from my engine.:) I noticed i had a bigger gain with higher RPMs, like when on the highway.
http://www.dubnetworks.net/dubhost/d/750-1/vwintakedone7.JPG
==========================
I hope this guide helped you. It was fun trying to figure out how to install the Air Intake that i purchased. I also bought a Front/Rear strut bar and would be happy to post another thread on how i installed that. If you haven't noticed, you can browse my photo album from the pictures that i have posted. Its still in the works, and i have more pictures that i need to upload.
What do you guys think of my Golf so far? Any comment would be appreciated!
http://picasaweb.google.com/Zeuslotion86/GolfProject/photo#5131826927819879986
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