Sunday, June 3, 2012
1999.5 Volkswagen Golf/GTI 2.0 L 2005 – 4 cylinder. Cold air system installation
Install the AEM cold air system
a) when installing AEM intake, twist the hose clamps, MAF sensor do not fully meeting or Assembly hardware tab until instructed to do later in these instructions.
b) install the rubber in the outermost (direction drivers side of vehicle) mount holes on the rear of the large opening behind the headlight. The rubber mount from the bottom (fig. 16) insert and secure it with a great fender washer and lock nut from the top. (Fig. 17)
c) place a large fender washer on the stud who originally protected the lower feed tube in place. (Fig. 18)
d) reinstall the MAF sensor in the plastic intake hose, rotate the electrical connector to the original position. Use the original hose clamp spring. Note: it is possible to install the MAF sensor backward. DO NOT INSTALL BACKWARD. Make sure that the end with the flange (originally in the airbox) is still facing away from the throttle body. If you don't already know, there is an arrow with the word "flow" molded into the body of MAF sensor. (Fig. 19)
e) install the hose on the top of the pipe AEM intake with one of the 2.75 "hose clamps. The top is the end with the AEM decal. Loosely install the second 2.75 "hose clamp on the hose silicone.
f) feed the AEM intake pipe in the engine Bay and fender well. The lower bracket should line up with the rubber mount installed in step 3b. The upper mount needs to line up with the originally used for assembling the lower standard stud.
g install a large fender washer) and lock nut on both the mount rubber and the stud. (Fig. 20 & 21) See the following chart for good rubber mount installation.
Insert the MAF sensor in the h) in the hose silicone on the AEM intake pipe. Make sure the MAF sensor is still properly rotated in the factory position. The MAF sensor wire connector in place.
i) AEM air filter on the bottom of the AEM intake pipe using the supplied hose clamp installs. Make sure that the filter does not contact the Horn or the plastic fender liner. (Fig. 22)
j) customizing the intake system for best editing and snug the hose clamps and swivel down. (Make sure no part of the intake system in contact with any part of the vehicle).
k) connect the factory breather hose to the AEM vacuum hose adapter. The clips on the plastic hose line up with the flats machined in the adapter. (Fig. 23) It may be helpful to lubricate the o-ring with a small amount of clean engine oil. Be careful to avoid damaging the o-ring.
l) install the supplied 5/8 "vacuum hose section of the AEM adapter to the nipple on the back of the pipe AEM intake with the two included 1" hose clamps. Route the hose in a wide arc under the AEM intake prevent pipe nodding. (Fig. 24)
m) re-assemble of the vehicle in the reverse order of disassembly. The large plastic cover behind the headlights which was retained by the three plastic rivets does not need to be installed.
n) currently the whole intake tube and filter can re-adjusted for position and alignment. Make sure that no part of the AEM intake rubs everywhere along the length. There are critical points to check on the corner of the plastic battery box and on the bend in the pipe just above the air filter.
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