77TSI Custom air filter: How To

[jaedencook]

This was in another thread but I've moved it here in the hope its easy to find for anyone who needs a starting point for this sort of thing.

My custom air system - The final product:




The old Air filter for those that haven't popped it open to see, the 77TSI doesn't use a panel filter... there is a panel filter listed on K&N, but its for the N\A model of polo or 1.4:




Our idea came from the fact that the old filter is a pod shape, held into place against the TOP pipe entrance of the air box facing the bottom of the box (so straight up and down.) It was held with a screw mechanism, so twisting the whole filter to the left popped it off.
We then used some screws to mount a pod filter adapter plate over the part where the old filter screwed on:




The end result meant a pod filter (K&N) could be affixed to the plate and covering the entrance exactly where the old one sat.

First off:

Undo the butterfly clip holding the intake pipe to the airbox and pull the pipe off, I've also marked the PCV pipe, this is very fragile as the part where it connects to the main intake pipe is held with very thin plastic on the inside, handle with caution.



Undo the 6 screws holding the top of the air box down:


Now the rest I don't have pics of but once you've gotten this far and so long as you apply common sense (and if I'm typing this descriptively enough of course) then the remainder should all make sense enough..
Take the top of the airbox off, the old filter is attached to this and will also come out with it - lift it straight up.
While holding the removed piece of airbox, twist the old filter to the left. The entire thing will pop off.

You can now fix the Pod adapter plate over the hole that the old filter covered. From there attach the Pod filter, now we tried various different filters (straight, pod and cone) what we found to fit the odd shape of the box most was the cone filter, it isn't quite as deep as a full pod filter and had the perfect circumference to fit into the bottom half of the airbox (Notice also that there is a cylindrical piece of plastic that come UP from the bottom of the airbox, this stopped us from being able to fit deeper filters.
Those daring enough feel free to cut it. But my goal was to do this without too much destruction of the original setup.

The two products I used:



When buying the adapter be sure to check the circumference of the hole that the old filter covered so that you can match it and not have any leaks. i believe it was a 3" circumference but I could be wrong.



I'm open for suggestions on improvement, but please; constructive criticism only.
If anyone has questions I'm also open to PM and can give out my mobile number too.

You'll probably notice my filter it pure silver... thats because I'm trying out the new stainless steel filter range, it uses a very very tight weave of metal instead of fabric and metal, the advantage is no fabric at all means much much less restriction on airflow and an easy hose out to clean it... some might argue that it wont catch all dirt or might let drops of moisture through, but in my opinion anything getting past the weave on that baby would likely get through fabric weave anyway and as for moisture, it would likely dry out from the airflow and atmosphere in the piping long before it gets anywhere else... unless you jam hose down there

[Casper]

Thanks for the write-up! Can you give us an idea on prices?

Also, do you know the actual part numbers of the filter and adaptor? Thanks again!

[Eshreff]

Good work, and which brand is that steel cotton filter?

By the way;

If you are familiar with Pipercross foam filters, they have released new filters for TSI-TDI engines. 2010-11 Polo's are using POD filters i guess. The Pipercross PX1819 is suitable for new Polo, ibiza, fabia airboxes (but check the filter shape first)

Pipercross have just released two new panel filters for the VAG market and to make it even better we are the first performance filter company out with one of them!
The two new filters are available now and fit the following vehicles:
PX1818 – VAG 2.0 FSI, 1.2 TSI, 1.4 TSI Golf, A3, Leon variants @ £44.99 inc. vat
PX1819 – VAG 1.2/1.4 TSI & TDI Polo, A1, Ibiza, Fabia @ £59.99 inc. vat EXCLUSIVE, the first performance air filter for this model!!!
Both the filters use identical fittings to the OE part so fitting is a breeze, so do your engine a favour and let it breath a sigh of relief with a new Pipercross air filter.

[jaedencook]

Can't say I'm familiar with them, I'd be interested to find a reseller to have a look at the material.
The brand i used is DRIFT, total for my modification was 90 bux.
I don't have the part numbers anymore but i can give the Autobarn part numbers if anyone wants them?

[Casper]

I don't have the part numbers anymore but i can give the Autobarn part numbers if anyone wants them?

Yes please!

[jaedencook]

PE10660 D1-30594925-US

Is the air filter

PE10670 D1-PA-11

Is the adapter plate.

The numbers are from the reciept and should be what Autobarn use to inventory the products.

[Gambit]

Ah i see what you have done, and its a great idea. Retain the airbox and place a higher flow pod filter in it.

[Hooti3]

Noticed any increase in induction noise?

[jaedencook]

Actually I was listening to it this morning on my way to work... I think the turbo spool has got louder, sounds bigger and has a definate louder woosh sound.

As for the sucking 'induction' sound, definantly an improvement. There would be even more so with a fabric K&N filter (as mine is all metal.)

Another thing I've noticed is a deep gruntier note from the engine and even idling there is a deeper exhaust note when you stand behind the car.

[bigfoot]

If you are familiar with Pipercross foam filters, they have released new filters for TSI-TDI engines. 2010-11 Polo's are using POD filters i guess. The Pipercross PX1819 is suitable for new Polo, ibiza, fabia airboxes (but check the filter shape first)

have you tried one of those yet Eşref bey?