DIY installation of Volkswagen Racing Cold Air Intake (CAI) to suit 2011 Golf "R"

[ozmale]

DIY installation of Volkswagen Racing Cold Air Intake (CAI) to suit 2011 Golf "R". Kit supplied by Rennenhus.

Please go here. Post #32 for a useful modification to the installation of this CAI.
http://www.vwgolf.net.au/showthread....1-Golf-R/page4

A Printable PDF of this DIY is available here:-



I received all the bits in the photo below except the part arrowed. Not needed for the "R".
Hazards: 1 cut finger and a bleeding knuckle.



The installation was not as easy as I expected but can be done with a little time and perseverance. As I pay close attention to detail and getting things right, the secret to this installation is keep on test fitting each part several times as you go. The application a petroleum jelly allows the silicon parts to slide nicely.

Ensure engine is off and keys removed. Good idea to get a blanket as you will need to do a lot of bending over the guards.

Remove the engine cover:-
Once all the connection points have been removed pull cover up firmly, one side at a time. It is held in place by 4 rubber donuts that fit down over cone shaped posts.





Remove the oval shaped flexible piece that attaches to the turbo.
You have to squeeze together the clip shown in the photo. It is a bitch. I used a pair of long nosed Vice grips.



After removal, this photo shows the bits you no longer need.



Prepare the angled silicon section to take the turbo bypass fitting.

Test fit the angled silicone onto the turbo then mark the best place for the aluminum bypass fitting.

The kit comes with a fitting and cutting instructions for the hole as shown below. I defy anyone to do a good job with the supplied cutter and instructions, mainly because its on a curve.



I used a drill and a wood bit, it cut a very nice round hole that just needed a little cleaning up with a Stanley knife.



You can then fit the bypass fitting as per instructions.
If you are concerned about this fitting coming lose you can secure the fine thread with locktite and it will never come undone.



Fit the angled assembly and secure with the supplied screw clamp. Take time to position the screw clamp it MUST be fitted straight and square otherwise it can slip on the slippery silicone.



It is now a matter of fitting the other parts and doing up the clamps when all is positioned correctly. Be sure to refit and connect the Air flow sensor.





The final securing of a fully assembled CAI is done with the strap in the photo below. The bracket is screwed to the brass fitting just at the base of the battery box. The brass inset post can be seen in the photo above.



And that is it your done.

Other photos show how the CAI fits with the 42DD catch can.

[Daneel]

Nice simple explanation with plenty of detailed photos. Great write up and an easy guide to follow Chris, thanks!

[Nathan_b]

Great write up mate - bit of a shame it's not made of carbon for that extra bit of bling haha!

[dyljoy]

Thanks for sharing, Chris. Still wait for my one.

[Brick]

Thanks for the write up Chris. Just waiting for mine to arrive. Hoping it is tomorrow so I can install on the weekend otherwise will have to wait another week.

Cheers

[zz2]

nice write up Chris.

ive done the install on many a mk5 and getting metal the press ring off the turbo inlet pipe is a f-ing skank of a task.



without the proper tool, i had to make do with vice grips. a lot swearing and bent hands later i managed to remove it. if you ever want to reinstall the OEM box for the love of god use a jubilee clamp

[ozmale]

zz2,

my car has not yet gone to the dealer for its first 15K service. If I send it there I will be returning to stock first.

WHAT IS A JUBILEE CLAMP ? I probably should know this but don't

Chris

[10d]

Good write up, Chris.

Seems in not the only one with issue using the supplied hole puncher for the hose.

[Daneel]

Jubilee clamp = hose clamp:



Jubilee is just a particular brand that's become synonymous with the product, similar to calling a tissue a Kleenex.

In case you're interested, Bunnings also sell them with little wings on the heads so you don't need a screwdriver to do them up/undo them.

[M4RK0]

This is sooo good Chris!! thanks for sharing!!