Safety first:
As always, when performing any work on your vehicle it is important that you
make safety your main concern. If using a jack, properly support the vehicle with
jack stands on each side. Never work under a vehicle supported only by a jack.
Note: The Following installation was done on a Volkswagen MKIV 1.8T Jetta.
Installation for other vehicles will be similar.
Tools Required:
Jack –optional
Jack stands –optional
#2 Phillips screwdriver
#2 Flat head screwdriver
Socket wrench
10mm socket
13mm socket
10” socket extension
10mm open end wrench
Preparation:
Park the vehicle on a level, suitable working area.
Be sure to put the vehicle in gear and/or in park and engage the parking brake.
Allow the engine time to cool to ambient temperatures to avoid the possibility of burns.
Step One: Removal of the factory air box.
Begin the installation by removing the two Phillips screws that secure the air box lid.
Next, remove the two Phillips screws that hold the mass airflow sensor to the air
box lid. Set the air box lid and filter aside.
Remove the bottom half of the air box by removing the two 10mm bolts that
secure it in place.
Step Two: Removal of the air duct and air duct
guide
Remove the 10mm nut securing the air duct to the fender, then remove air duct.
Remove the 10mm bolt holding the battery cover, remove the battery cover and
set it aside. Disconnecting the battery may require you to re-enter your radio
anti- theft code.
To get the air duct
guide (out lined) out from underneath the headlight, you must
take a 13mm socket with a 10” extension and remove the front battery hold down
bracket. The air duct
guide is held in place with 3 plastic rivet type pins, these
pins are in locations difficult to reach. Removal of air duct
guide with out
removing the pins will probably result in broken pins or air duct
guide.
Step Three: Installation of the cold air intake pipe
VERIFY THAT THE INTAKE PIPE IS FREE FROM ALL DUST, DIRT AND DEBRIS
PRIOR TO INSTALLATION.
To ensure intake pipe clearance, the clip must be removed from the inner fender.
Once removed, tuck it to the side.
Attach the intake pipe to the mass air flow sensor using the supplied silicone
hose connector and 3” clamps. Once satisfied with mounting position, tighten the
clamp secure the intake.
Position the lower support bracket as shown in the above picture and bolt the
bracket to the lower fender.
Then place the clamp in front of the bracket and tighten.
The above picture shows the bracket installed, and the intake positioned against
the bracket. Install the clamp around the notched part of bracket and silicone
coupler to secure lower half of intake.
Install the supplied cushioned loop clamp as shown.
Tuck connector out of the way, behind the intake pipe as shown.
When reinstalling the battery tray, be careful when positioning the wiring loom to
avoid pinching any wires.
Attach the High Flow Intake Filter to the end of the intake Pipe
Step Four: Breather Filter Installation
Clip the supplied adapter into the female breather tube that was previously
connected to the back of the air box.
Using zip ties, Secure the breather filter out of the way of all shifting and radiator
components.
Step Five: Finishing Up
Inspect and double-check your work: Be sure that all connections are tight, all
tools are accounted for, and all pieces supplied in the kit are used. Start the car
and let idle. Listen for any unusual noises. Once everything checks out close the
hood and go enjoy the added power and sound from your ECS XAS Cold Air
Intake Kit.