What have you done to your mk4 (golf/bora) today?

[Manaz]

Hey Rob, Can I order a couple of bits from ECS? What's the process, get you the numbers and send through the money??

Cheers

Gavin

Private Message sent. (I'd say PM, but then I'd fall foul of the 10 character rule...)

[Manaz]

Well, I knocked off one of the list of mods I've got queued up for my car today - the Euro R32 DSG air intake mod.

So, why would you do this mod?

If you're familiar with the air intake path on a Mk4 Golf/Bora, air comes in from behind the front left headlight into a snorkel which carries the air into the bottom of the airbox.

The entry into the snorkel looks like this (stock on left, R32 DSG version on right):




Quite a difference!

The snorkels continue the trend (I'm sure you don't need me to tell you which is which):






As you can see , the difference between the diameter of the snorkels is different in every dimension.

The theory is that the much thicker snorkel allows better air flow, which is always a good thing! This has been shown in the past by quozl and graeme86 (they did back to back readings from the MAF and found that the R32 DSG snorkel/airbox combo flowed as well as one particular well-fancied CAI/pod filter, though having been in goodfella's Bora recently, I'm sure there won't be as much grin-inducing induction noise!).

I forgot to take photos as I went, but basically, the process is as follows.

1. Open bonnet. Duh!
2. Remove the two plastic guards which are screwed to the top of the headlight assembly. The right side one is required, the left one gets replaced.
3. Remove existing airbox lid - to do this, you have to unscrew the MAF. Well worth disconnecting the MAF from the wiring loom at this point too, as that will help you to move bits around (it's needed).
4. Remove top of battery box (including fuses) and battery. My battery also had a hold-down which needed removing. Remember when removing a battery that you disconnect the NEGATIVE (blue) terminal first.
5.Remove bottom of airbox. It's screwed to the battery tray as well as the strut tower.
6. Remove battery try. Four screws in the bottom of it hold it down.
7. Remove snorkel. It's screwed to the side of the car, you need to

This should leave you with a nice open space in the front left corner of your engine bay. You should be able to clearly see your gear selector mechanism down on top of your gearbox, as well as your gearbox mount between the gearbox and chassis.

8. Remove the plastic shielding from behind the headlight. This is secured in place with three split pins - the easiest way to deal with them is to punch their centres right through, and then pull them out. It's apparently theoretically possible to reuse them, but I'm glad I bought replacements!

And that's everything that needs removing removed. Time to start reversing the process.

9. Replace plastic shielding behind headlight with the new part. Pushing the bottom split pin through is a PIG - I found it easiest to do by reaching up from under the car.
10. Fit new snorkel loosely. Wiggle room needed for later installation of airbox.
11. Refit battery tray.
12. Refit new bottom half of airbox. The snorkel has to slide into it, you'll have to twist the airbox into position. Line it up using the two attachment points (one's on the battery tray). Once it's in, screw it down, then tighten the snorkel attachment nut (you'll need a spanner, no room for a socket).
13. Replace battery/battery box/fuse box/etc. Negative terminal of battery gets connected last.
14. Place airbox lid onto airbox (old lid, to fit the MAF), and re-attach MAF. Do not forget to re-connect the MAF to the wiring loom - if you do, you'll get a fault code that you need to get cleared. Yes, I forgot.
15. Replace plastic guards that enclose the headlight assembly. You'll be using a new guard on the left side.

All done. Close bonnet and bask in the glory of a job well done!

I hope to get some VAGCOM logs of some runs (I have some previous runs logged) to confirm quozl and graeme86's previous findings.

[McDub]

I hope to get some VAGCOM logs of some runs (I have some previous runs logged) to confirm Al's previous findings.

nice, let us know how it goes.
im assuming the snorkel where it goes into the airbox is the same size as the origional one though?
and where did you get the parts from? and the split pins you need to get?


I heard a rumour today that after 5 months of my car not running right, it has finnally been fixed!
pick it up tomorrow, can't wait!

[fuzion]

manaz, im going to rain on your parade for the best option (imo) lol

http://bambergvr6.50megs.com/stock_airbox_cai.htm

but this method is the best for non intakes like mine, made a huge difference and stealth as well.





from the best thread for FAQ/DIY's on the net for our cars (http://forums.vwvortex.com/zerothread?id=1835863)

[McDub]

manaz, im going to rain on your parade for the best option (imo) lol

http://bambergvr6.50megs.com/stock_airbox_cai.htm

i've been thinking of doing this... what pipe do you reccomend?
obviously needs to not collapse under vacuum, but still be flexible...

i don't get how the standard intake gets any airflow behind the lights... this mod has basically moved it down to the lower grill, like where fog lights would go hasn't it?

[Manaz]

manaz, im going to rain on your parade for the best option (imo) lol

http://bambergvr6.50megs.com/stock_airbox_cai.htm

but this method is the best for non intakes like mine, made a huge difference and stealth as well.

http://bambergvr6.50megs.com/images/CAI_03.jpg

http://bambergvr6.50megs.com/images/CAI_02.jpg

from the best thread for FAQ/DIY's on the net for our cars (http://forums.vwvortex.com/zerothread?id=1835863)

It's another option, almost certainly cheaper and undoubtably a good one for many people, but I didn't choose it because:

1. I'm trying to stick to OEM as much as possible. I realise there's no requirement for me to do so, but it's the way I'm pushing with the car.

2. Although you're sucking air in from a different spot and potentially getting some "ram-air" effect (popular on motorbikes!), you're still restricted by the size of the hole as the new pipe enters the airbox. The DSG airbox has a much bigger (it'd have to be close to twice the cross-section!) hole for the air to flow in through, and that's the benefit I was looking for.

3. Shouldn't matter TOO much, but the air path looks longer and more convoluted than the OEM option. Would probably matter more if I was chasing the last few tenths of a percent for race work, but probably not a big issue on the road!

[Merlin8r]

Pulled out the intercooler and cleaned 9 years worth of manky oil out of it.

[Manaz]

Pulled out the intercooler and cleaned 9 years worth of manky oil out of it.

Has it had much impact on performance? Better flow through a clean core would have to be helpful, yes?

[gavs]

Washed my car yesterday and almost cried because the paint is so f**ked should have spent a few hours worth of polishing and waxing but really didn't feel like it....

[Merlin8r]

Has it had much impact on performance? Better flow through a clean core would have to be helpful, yes?

Feels like it's pulling a bit harder. Nothing huge but yeah, there's a little difference.