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Hi all, after the success of my Lupo mirror "how 2" I thought I'd do one for fitting the DSG intake.

Time wise was about 3 hours from total start to finish.

I accept no responsibility for your failures.. Proceed at your own risk.

First of all I'd like to say I forgot to take some pics so thanks to the people that let me use theres.

Tools I used where a socket set, a few different sizes of screwdrivers, dremel, sand paper, junior hacksaw and some sealant. I did this back in November so I think thats all the tools I used but there might be more.

You will need 3 parts and the part numbers are......

1J0 805 965 EB 41 - cover for behind headlight
1J0 805 962 GB 41 - Air Duct
1J0 129 609 G - Intake snorkel pipe

Pic of all 3 parts
2011-01-01210115.jpg


Reason for the mod is the air intake path on a Mk4 Golf/Bora is very small, air comes in through the grill in round behind the front right hand headlight into a snorkel which carries the air into the bottom of the air box.

In the pics below you can see the difference in the size of the parts.

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

IMG_3200.jpg


These two pics of the snorkel shows you the difference in size.

IMG_3196.jpg


2556258558_cf8008ec55_b.jpg


So lets get started.......

I removed the front bumper (took about 10mins) and it left me with this

SDC11515.jpg


Remove the 4 screws in the cover that sits behind the headlight. The right side one is required, the left one gets replaced. Remove the battery cover as well.

SDC11520.jpg


SDC11522.jpg


I then removed the headlight.

SDC11525.jpg


Removed existing air box, top of battery box (including fuses) and battery. Remember when removing a battery that you disconnect the NEGATIVE terminal first.

SDC11528.jpg


Remove bottom of air box. It's screwed to the battery tray as well as the strut tower. At this point I also removed the battery try. Four screws in the bottom of it hold it down and the snorkel. It's screwed to the side of the car.

SDC11531.jpg


SDC11543.jpg


This should leave you with a nice open space in the front left corner of your engine bay. So you can remove the plastic shielding/Air duct 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 possible to reuse them (this is what I did) but it might be a good idea to get some replacements. In the pics below it shows you where there at, 2 up top 1 below.

SDC11532.jpg


SDC11538.jpg


SDC11539.jpg


And that's everything that I removed. Time to start reversing the process and getting your new parts fitted.

At this point I started to smooth out my air box using a dremel and sander paper. I only done the bottom part but will do the top soon.

SDC11548.jpg


SDC11549.jpg


You will also need to take the DSG intake pipe and traced around it on the air box to cut out a bigger hole so it fits. (thanks Roachie for the pic)

DSGinduction004.jpg


Replace the plastic shielding/air duct behind headlight with the three split pins. Pushing the bottom split pin through is a PIG - I found it easiest to do byreaching up from under the car..

Fit new snorkel loosely - wiggle room needed for later installation of airbox.

Refit battery tray.

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 itdown, then tighten the snorkel attachment nut (you'll need a spanner, no room for a socket).

SDC11547.jpg


Once I was happy with the shape of the snorkel in the air box I sealed it to make sure it had no gaps.

SDC11557.jpg


SDC11559.jpg


Replace battery/battery box/fuse box/etc. Negative terminal of battery gets connected last and the top of the air box.

SDC11560.jpg


I then got to work on the bit thats at the start of the intake by using the dremel, sand paper and junior hacksaw. There can be a lot of dust so you may want to get the hoover out.

SDC11563.jpg


SDC11569.jpg


Replace the headlight, plastic guards that enclose the headlight assembly (the new one you got) Battery cover and front bumper.

SDC11571.jpg


That's the job done time for a beer, sit back and tell yourself how amazin you are for doing all the above..lol

Thanks for reading and I hope this helps some one out. As all ways C&C welcome and feel free to add away to this H2.
 

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Discussion Starter · #6 ·
Cheers guys... price wise I cant remember 100% but think it was under £30.

Theres not much of a noise gain with doing this but did see on another forum that the DGS intake flowed as well as one particular well-fancied CAI/pod filter.

At the time I did this I fitted a full Milltek and with the both done the car feels different to drive as in you know its breathing a lot better if you know what I mean.
 

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pauly4226
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did this to my v5 bora a while back,am sure it makes a differance,gets to about 4300 and the rev counter goes mad,lol just ask mak-iv
 

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Discussion Starter · #13 ·
Thanks lads.. Will be doing another on in a while for fitting the S3 upper brace.

Forgot to say that the battery cover sits up a bit after you have the new parts fitted but you cant sort this by trimming the side of it.
 

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Excellent write up... I just looked into it for my TDI and it'll cost me about $65 for all the parts, so I'll definitely be doing it too.

Is the R32 air box bigger too???
 

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my Hid wires are in the way and blocking the snorkel i have now. Im just tempted to get some venting duct hose.. and running it down to the bottom of the bumper.....?
 

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Excellent write up... I just looked into it for my TDI and it'll cost me about $65 for all the parts, so I'll definitely be doing it too.

Is the R32 air box bigger too???
The R32 DSG airbox is not any bigger physically.

The inlet side (where the snorkel goes in) is obviously bigger, but that's all.
 
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