Author Topic: Smooth your airbox / Fit the R32 DSG intake.  (Read 37396 times)

Offline richw911

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Smooth your airbox / Fit the R32 DSG intake.
« on: 29 July 2008, 23:03 »
The point of this mod is to remove all the excess plastic inside the stock air box to create the most volume for air to flow through and to remove anything that would create air turbulence.

You should the difference with this mod however there is a lot of debate on here and other sites as to whether it does work or not. Horses for courses - make your own mind up.


This is the inside of the stock air box. (Its actually a bora airbox so yours will be a bit different!!  ) Note the small drill holes.



If you look through the side of the air box where the 'snorkel' attaches you can see all the plastic that air has to maneuver over and around.



Use wire cutters  to cut as much of this excess plastic out as you can, then sand what is left down level and smooth with the Dremel/chisel.



This is what the air box will look like after all that is removed and sanded.  It is not pretty, but it is functional. 
Use the drill to place a few more small drain holes.




The R32 DSG intake is also a nice little mod lets more cold air into your airbox as its a lot bigger.

: http://www.vwspeed.co.uk/volkswagen/vw-parts/DSG_Genuine_VW_Intake_Kit-2260-19.html


Mk4 Golf R32 DSG Intake Upgrade parts from vw:

-Adjuster  1J0805965EB41

-Air duct  1J0805962GB41

-Pipe  1J0129609G



Its fairly straightforward to fit,

unlock car
open bonnet
remove torx screws (T20) within each arch liner (4) (need to turn the wheel lock to lock for each side
remove the two outer lower grills and remove torx screws (T30)
unclip the grill - 3 clips along the bottom, two on the top at each side (you can then just leave it hanging
remove the 5 screws and then pull the bumper off
disconnect battery and remove
unclip headlight wiring and undo 4 torx screws and remove headlight
unclip airbox hose
undo airbox cover
undo bolt holding down airbox and remove airbox
remove old pipe
for the intake part behind the headligh there are three plastic pop rivets - use a thin screwdriver and push the middle out of each of them (stand in front of the car) and then remove
mark out where you need to cut the airbox (to take the larger pipe)

Fitting is reversal of removal  :afro:

Few pics of the difference in size:



  :shocked: :afro:


The writer of this guide and GolfGTI.co.uk accept no responsibility of damage to your car when using this guide. Use at your own risk.
« Last Edit: 21 July 2012, 18:39 by richw911 »

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Offline Hulmie

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Re: Smooth your airbox.
« Reply #1 on: 23 August 2008, 23:13 »
what panel filer would be recommending to use with this mod?


mk4 R32 Golf, Reflex Silver, V6

Offline richw911

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Re: Smooth your airbox.
« Reply #2 on: 23 August 2008, 23:16 »

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Offline Pete H

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Re: Smooth your airbox / Fit the R32 DSG intake.
« Reply #3 on: 21 March 2009, 08:55 »
couple of questions, first off the base of my airbox looks nothing like that one pictured :huh:well the difference is the part on the left, the only hole in it is the same as the one on the right.

also the small holes put into it, are they just extra drainage holes for water?

Offline (shakey)

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Re: Smooth your airbox / Fit the R32 DSG intake.
« Reply #4 on: 21 March 2009, 21:15 »
couple of questions, first off the base of my airbox looks nothing like that one pictured :huh:well the difference is the part on the left, the only hole in it is the same as the one on the right.

also the small holes put into it, are they just extra drainage holes for water?

are you lookin at the box the right way round sorry to be rude but they shud all b the same.

yes

Offline richw911

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Re: Smooth your airbox / Fit the R32 DSG intake.
« Reply #5 on: 21 March 2009, 21:33 »
couple of questions, first off the base of my airbox looks nothing like that one pictured :huh:well the difference is the part on the left, the only hole in it is the same as the one on the right.

also the small holes put into it, are they just extra drainage holes for water?

Quote from thread " Its actually a bora airbox so yours will be a bit different!!  "  :wink:

You don't have to drill holes if you dont want to. :smiley:

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Offline mart08uk

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Re: Smooth your airbox / Fit the R32 DSG intake.
« Reply #6 on: 06 April 2009, 00:44 »
also the small holes put into it, are they just extra drainage holes for water?

No, to allow more air in, and sounds different becuase it sucks through the small holes, and water should definitely not get into the air box.

Offline Voodoo-Music

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Re: Smooth your airbox / Fit the R32 DSG intake.
« Reply #7 on: 08 April 2009, 19:54 »
I have had problems with this, i understand where the airbox sits and the intake pipe but the other parts, what are they for ?

I cant figure out where the adjuster and air duct sit, i have ther32 front bumper

Offline richw911

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Re: Smooth your airbox / Fit the R32 DSG intake.
« Reply #8 on: 08 April 2009, 20:07 »
I have had problems with this, i understand where the airbox sits and the intake pipe but the other parts, what are they for ?

I cant figure out where the adjuster and air duct sit, i have ther32 front bumper
The other part go's around by the headlight.  :smiley:

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Offline Voodoo-Music

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Re: Smooth your airbox / Fit the R32 DSG intake.
« Reply #9 on: 08 April 2009, 20:11 »
Is there a pic of it so i can see how it fits. Really stuck with putting it together