Contents: Petrol engine 1.4 l ⬇ Petrol engines 1.8 and 2.0 l ⬇ Petrol engine 3.6 l ⬇ Diesel engines 2.0 l TDI-CR (CFFB,…⬇ Diesel engines 1.9 l TDI-PD (BXE,…⬇
1. Description of replacement of the filter element is given in Section 16 Chapter 1. The following describes the procedure for removing the air cleaner assembly.
Petrol engine 1.4 l
2. Details of installation and assembly of the air cleaner are shown in the accompanying illustration.
4.2 Installation and assembly details of the air cleaner for a 1.4 L petrol engine
1 Air cleaner cover
2, 3, 11, 13 Bolt, 2 Nm
4 Holder
5 Filter element
6 Rubber-metal support with captive screw, 8 Nm
7 Seals
8 Air cleaner housing
9 Rubber support
10 Inlet connection, with cover
12 Air intake
14 Spring band clamp
15 Air hose, to turbocharger
16 Vacuum hose, to cylinder head cover
3. Press the clamps (arrows in the accompanying illustration) and remove the cover (1) from the intake connection. Separate the intake connection from the air intake, loosen the clamp (2) and remove the air hose from the turbocharger.
4.3 Air Cleaner Connections
4. Disconnect the vacuum hose from the air cleaner housing (1 on the accompanying illustration), unscrew the bolt (2) and remove the air cleaner from the supports (3) in an upward direction.
4.4 Vacuum Hose and Air Cleaner Fasteners
5. Installation is carried out in reverse order.
Petrol engines 1.8 and 2.0 l
6. Details of installation and assembly of the air cleaner are shown in the accompanying illustration.
4.6 Installation and assembly details of the air cleaner for 1.8 and 2.0 l petrol engines
1 Spring clamp
2 Inlet hose, to turbocharger
3 Air flow sensor "G70" with IAT sensor No.2 "G299"
4, 5 Captive cover bolts 6, 1.5 Nm
6 Air cleaner cover
7 Filter element
8 Captive air cleaner housing mounting bolt, 8 Nm
9 Snow guard, not on all models
10 Air cleaner housing
11 Hose connection 12
12 Drainage hose
13 One-way (overflow) valve
14 Connecting hose, to bonnet lock holder
7. Remove the top engine cover.
8. Release the clamps (see illustration 3.19 Chapter 3) and remove the connection cover.
9. Remove the bolts (arrows in illustration 3.20 Chapter 3) connections (1) and remove the connecting hose (2) from the guide. Remove the air intake.
10. Disconnect the connector (2 on the accompanying illustration) combined sensors, loosen and pull off the clamp (1), unscrew the bolt (3), loosen the two guides of the air cleaner housing and remove it upwards from under the upper coolant hose.
4.10 Removing the air cleaner for 1.8 and 2.0 L models
11. Installation is carried out in reverse order.
Petrol engine 3.6 l
12. The details of the air cleaner installation are shown in the accompanying illustration.
4.12 Engine Air Cleaner Installation Details 3.6
1 Spring clamp
2 Air hose to throttle module
3 Air flow sensor "G70"
4, 7, 13 Bolt, 2 Nm
5 Sealing ring
6 Air cleaner cover
8 Supports, in the cover 6
9 Bolt, 8 Nm
10 Lid
11, 12 Air intake
14 Gasket
15 Rubber support
16 Bolt, 10 Nm
17 Air cleaner support
18 Air cleaner housings
19 Filter element
Diesel engines 2.0 l TDI-CR (CFFB, CFGB and CLJA)
13. Details of installation and assembly of the air cleaner are shown in the accompanying illustration.
4.13 Installation and assembly details of the air cleaner for 2.0 TDI-CR diesel engines (CFFB, CFGB and CLJA)
1 Inlet hose, to turbocharger
2 Ventilation tube support, heated (only for countries with cold climates)
3 PCV connection pipe
4, 19 Bolt, 2 Nm
5 Air flow sensor "G70"
6 Sealing ring
7 Cover mounting bolts 11.2 Nm
8 Housing mounting bolts 13.8 Nm
9 Bushing
10 Washer
11 Air cleaner cover
12 Filter element
13 Air cleaner housing
14 Connecting the drain hose
15 Bypass valve
16 Drainage hose
17 Connecting hose
18 Air intake, mounted on the hood lock holder
20 Air intake duct
21 Air duct cover 20
22, 23 Spring plastic clamp
24 Inlet connection, with locking screw, 9 Nm
25 Sealing ring, must be replaced
14. Remove the top engine cover.
15. Release the clamps (see illustration 3.19 Chapter 3) and remove the air intake duct cover.
16. Remove the bolts (arrows in illustration 3.20 Chapter 3) of the air intake duct (1) and remove the connecting hose (2) from the guide.
17. Press the latches (1 and 3 in Illustration 6.12 Chapter 3) and pull the connecting hose (4) out of the air cleaner (2).
18. Disconnect the connector (1 on the accompanying illustration) mAF sensor, disconnect the vacuum hose (3) and the turbocharger inlet hose (2). Loosen the bolt (4) and remove the air cleaner together with the MAF sensor.
4.18 Removing the air cleaner
19. Installation is carried out in reverse order.
Diesel engines 1.9 l TDI-PD (BXE, BLS)
20. The details of the air cleaner installation are shown in the accompanying illustration.
4.20 Installation and assembly details of the air cleaner for 2.0 TDI-CR diesel engines (CFFB, CFGB and CLJA)
1 Inlet hose, to turbocharger
2 Air flow sensor "G70"
3 Sealing ring
4 Bolt, 2 Nm
5 Air cleaner cover
6 Vacuum valve block ventilation hose
7 Filter element
8 Air duct, from the hood lock holder
9 Air cleaner housing
10 Bolt, 8 Nm
11 Drainage hose