Modyfing the Air Box

NOTE: This is a modification for the VR6 Air Boxes only. The G60's do not have the mesh filter or the snorkel. They only have a straight tube that connects to the back of the light. But this may be also taken out. Some (Jan) say it is too noisy.

from:lobo@nando.net (Matt Ridge)

The article begins on page 52 of EC from July '95. The modifications are done to a Jetta GLX and vary slightly for the Corrado. You will probably need a medium length screwdriver to pry open the clips that hold the box closed (this is actually the most difficult part of the procedure). Once you get the top loose, unscrew the two screws that hold the airflow sensor to the box top and slide the top off of the sensor. Now I had to remove a 10mm screw holding a A/C tube to the inside of the fender. With this screw out, the tube can be moved out of the way to allow easier removal of the air box top. After you get the top out of the car, remove the air filter and you will see a oblong shaped fine wire mesh screen covering the air inlet. This is the screen EC talks about, but it looks a lot different than the pictures. To get at it, I removed the air entire air box by popping the two rubber bands (actually two big O-rings) off of the hooks - be careful not to let them drop into the engine area. With the box removed, you have to remove the entire inlet tube from the box. I think it slides right out - I can't remember. The screen is now accesible from all sides. My screen was riveted in (3 or 4 places) and I did not have a drill handy so I pried and basically ripped the rivets out with a screwdriver. I ended up pretty much mangling the screen, so if you plan on putting it back in, you should drill out the rivets. The box goes back together in reverse order.

The "snorkel" tube in the air box top is easily removed by hammering it out (from the inside of the box out). I did both of these mods at the same time so I don't know which one caused the majority of the power improvement.

Good luck - I think it is worth the time!

P.S. Two people that have also done this mod responded to my e-mail by telling me that everything should be OK, but I probably want to replace the air filter with a K&N or Amsoil one. I planned on this, but have not yet done it.


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