1999-2005 System Installation Volkswagen Golf/GTI 2.0L 4 Cyl Cold Air

Getting Started
a) Make sure vehicle is parked on a level surface.
b) Set parking brake.
c) Jack the front of the vehicle and support with properly rated jack stands.
d) Lift the plastic battery cover and disconnect both battery terminals. Remove the short positive lead from the positive battery terminal. (Fig. 1)
e) If engine has run within the past two hours let it cool down.

2) Removing the stock air inlet system
a) Swing the fuse box on top of the battery upwards and remove the hinge from the plastic battery box.
b) Remove the four screws along the top of the radiator support. (Fig. 2) Remove the two plastic covers.
c) Remove the battery hold down bolt and remove the battery from the vehicle. (Fig. 3)
d) Remove the three bolts that secure the plastic battery box in place. Two bolts are located at the rear of the battery, on either side of the plastic wire tunnel. The third bolt is located on the radiator side of the battery. (Fig. 4)
e) Unlatch the plastic wire tunnel cover on the backside of the battery box. (Fig. 5) Swing the cover open and remove the wire harness for the plastic battery box.
f) Remove the plastic battery tray from the vehicle by removing the four bolts that secure it. (Fig. 6)
g) Unplug the wire connector from the MAF sensor. (Fig. 7)
h) Loosen the spring hose clamp that secures the inlet tube to the MAF sensor. Pull the inlet tube clear of the MAF sensor. (Fig. 8)
i) Remove the breather hose from the air box by squeezing the plastic tabs to release the fitting. Use care to avoid damaging the o-ring. (Fig. 9)
j) Remove the nut that secures the lower intake tube to the inner fender well. (Fig. 10)
k) Remove the two bolts that secure the air box. (Fig. 11) Remove the air box, MAF sensor, and lower inlet tube from the vehicle.
l) Remove the two screws securing the MAF sensor to the air box and set the MAF sensor aside in a safe place where it won’t be damaged.
m) Remove the screws securing the driver’s side fender liner in place. Fold the fender liner back and out of the way to allow access to the area behind the front bumper.
n) Remove the plastic cover behind the driver’s side headlight. The cover is secured with three plastic rivets. The rivets are released by pushing the center of the plastic rivet with a small, pointed object. Two rivets are located at the top of the plastic cover, in the radiator support. (Fig. 12) The third rivet is accessible from under the car. (Fig. 13) Pull the plastic cover out of the engine bay. (Fig. 14)
o) Remove the ground cable from the plastic clip in the fender well. (Fig. 15)

pdf 1999- 2005 Volkswagen Golf/GTI 2.0L 4 Cyl Cold Air System Installation