Air Box removal

morrismen · Post by **morrismen** » Thu Sep 16, 2004 4:29 pm

OK, this may sound really dumb, but how does one remove the standard Air Box (filter) from the Polo GTI

I know there's this big black flat plastic box over the top of the engine

, and I've found 4 hex bolts... do I undo these? If so, I'm gonna need a much longer allen key

Do I have to watch out for any wires/gaskets etc that may be attached

Si_GTi · Post by **Si_GTi** » Thu Sep 16, 2004 4:35 pm

Can't help you mate, although I'd be interested to find out how the airbox is taken out too! This is why Haynes should have sorted out a manual

M@Turner · Post by **M@Turner** » Thu Sep 16, 2004 7:03 pm

Its quite simple really. There are two screws attached to the piping which feeds air to the box. Remove them. Then you'll have to remove the top cover of your air box. 6 or 7 screws situated around the side of the box. After you've taken the top off, you should be confronted by the filter. Remove the filter simply by pulling it off, and you should see an Allen key style bolt that needs to be removed. After this it should simply be just a matter of tugging at the bottom half of the box, so that it comes away from the throttle body.

From what i can remember this is how i did mine. Took about 5 mins.

Any probs send me a PM.

ICEYPOLO · Post by **ICEYPOLO** » Thu Sep 16, 2004 8:58 pm

easier way.... undo the two bolts holding in the piping to the box, then get a screwdriver and pop off the little cover on the top of the box where you'll see a 5mm alen key bolt (you'll need a srewdriver attatchment as its deep...

then jus pull it off in one piece, it is stiff to pull off as its pressed over a 'ball joint' on the inlet manifold....

only did it yesterday to put the BMC on

scott

morrismen · Post by **morrismen** » Thu Sep 16, 2004 8:58 pm

I can see the 2 screws for the air intake pipe... but I could only see 4 hex bolts last time I looked; 2 at the front of the box which seem to be bolted into the rocker cover. I guess I shouldn't unbolt these then

Gonna need to have a look for the 6-7 screws around the edge of this box system now.

Cheers - I may be back to you

ICEYPOLO · Post by **ICEYPOLO** » Thu Sep 16, 2004 9:03 pm

dont bother with these bolts its only to take the top off which you dont need to do! trust me you're making more work for youself!

scott

M@Turner · Post by **M@Turner** » Fri Sep 17, 2004 10:23 am

Come to think about it, ICEYPOLO's way is much simpler. When i was removing my air box to fit my BMC, i didn't notice the bit of plastic which can be removed.

morrismen · Post by **morrismen** » Fri Sep 17, 2004 12:41 pm

Ok, maybe I should start this again.

I can see 4 hex bolts that bolt into the rocker (front top of engine where the 16V badge is).

This holds down a black flat top cover with the VW badge on and it's located in place at the back with 2 big circular clips which pull off pipes easily to release this...

So, do I have to remove the 4 x hex bolts cos I can't see anyway of getting to what appears to be the air filter box underneath otherwise.

Seems a lot of effort to remove an air filter???

More info needed please

and speak to me as if I'm a dummy about this please

Cheers.

gti MAD · Post by **gti MAD** » Fri Sep 17, 2004 1:21 pm

HI

Firstly you will need to remove the 4 allen bolts you can see then lift off the engine cover,

once this is out of the way you will be able to see what you are doing, remove the 2 screws securing the cold air feed and pull this free.

there is now 2 options either undo the 7 screws around the top of the filter box and lift off the lid or remove the cap on the top either way allows you to gain access to the securing bolt.

undo this bolt and also the one at the front of the filter box at the back of the rocker cover.

pull off the engine breather pipe

the filter box can now be lifted straight up and off, it will be tight as it sits on a lug on the inlet manifold

morrismen · Post by **morrismen** » Fri Sep 17, 2004 3:31 pm

Good Stuff gti MAD... You're talking my kind of language.

BIG Thanks to all

DMWRIGHT · Post by **DMWRIGHT** » Fri Sep 17, 2004 5:55 pm

http://www.tyresmoke.net/ubbthreads/sho ... o=&fpart=1

Post by **Josh_PoloGTi** » Fri Sep 17, 2004 6:42 pm

ERRRRM!!!

In the 1st video clip, what's that nasty noise like a toothless cog?????

Sorry to be alarmist, but it didn't sound well

Prash · Post by **Prash** » Fri Sep 17, 2004 6:53 pm

Josh_PoloGTi wrote:ERRRRM!!!

In the 1st video clip, what's that nasty noise like a toothless cog?????

Sorry to be alarmist, but it didn't sound well

hmm it did sound a bit transit van like at the bottom of the rev range, although mine sounds a bit rubbish below about 2700

DMWRIGHT · Post by **DMWRIGHT** » Fri Sep 17, 2004 7:58 pm

Well spotted, cam belt tension on the way out, been replaced by VW since under warranty at a massive cost to them, (and aparently lose exahaust mainfold)

Doesn't sound like that anymore thank god !

Post by **Josh_PoloGTi** » Fri Sep 17, 2004 9:20 pm

Oh thank god you've sorted it!

My cam belt tensioner went on my old GTi...

The cam belt almost fell off it was that bad (but VERY luckilly for me I spotted it in time before it did any damage)!!

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Air Box removal

Air Box removal

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removing the airbox

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