www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2016 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You

Order your TDIClub merchandise and help support TDIClub


Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW B5 Passat TDIs

VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

Reply
 
Thread Tools
Old April 6th, 2009, 02:13   #1
SUNRG
Veteran Member
 
SUNRG's Avatar
 
Join Date: Oct 2003
Location: Roanoke, VA
Fuel Economy: 28mpg@74mph: 1995 Volvo 850 Turbo Wagon
Default How To: Air Intake Screen Mod

The pre-filter screen in B5.5 Passats does a fantastic job of keeping large contaminants away from the primary air filter. However, the pre-filter can become partially or completely obstructed by debris very quicky:


One remedy for this issue is to hang a section of heavy duty screen in front of the air intake to prevent large contaminants from reaching and potentially blocking the very fine mesh pre-filter screen. Following is the procedure for the "Air Intake Screen Mod".

Pick up some Pet Resistant (Very Heavy Duty) Screening:


[Note: I bought this whole roll just for this project so I have a ton of it left over. If anyone's in the Roanoke area or plans to attend Impex Fest I'll gladly let you cut a section or two from the roll.]

Cut out an approximately 11.5" square section of the screen:


Remove the three screws that secure the air intake, then slide screen section down behind the grill directly in front of the air intake. The bottom of the screen should extend down well below the bottom of the intake to ensure debris cannot get behind the screen.

Insert Screen:


Cut tiny holes in the screen to thread intake-securing screws through, tighten the screws down and trim away the excess screen material.

After Trimming:


Thru-Grill View:


Overview:


Done.

This mod should completely prevent pre-filter screen clogging. This screen can be very easily removed, cleaned and reinstalled.

Cheers! Rob
__________________
ECO-DRIVING - advanced driving techniques contributing to sustainable mobility. Links 1 - 2 - 3 - 4 - 5
Bicycles, lots of them, mpg | 05 VW Passat Wagon GLS TDI ~36mpg

Last edited by SUNRG; April 6th, 2009 at 02:22.
SUNRG is offline   Reply With Quote
Old April 6th, 2009, 09:02   #2
abctdi
Veteran Member
 
abctdi's Avatar
 
Join Date: Mar 2004
Location: ABQ, NM, USA
Default

That's basically what I did. One time I smashed a large tumbleweed and spent an hour picking pieces out of everywhere, including the airbox. That inspired me to screen it.
__________________
05 Passat GLS 2.0 PD, UnChained & Steel GPs by VW, 15" steelies, New TB/WP, motor mounts, alt pulley, trans filter, cv boots, TSB #P9/66C8, clear bra & tint, both raxles. Now only driven 1-2 times per week. 123k miles (sold)

DD is a 2012 Kia Optima SX turbo with 274 hp and 269lb-ft@1,750-4,500rpm
abctdi is offline   Reply With Quote
Old January 22nd, 2010, 05:55   #3
SUNRG
Veteran Member
 
SUNRG's Avatar
 
Join Date: Oct 2003
Location: Roanoke, VA
Fuel Economy: 28mpg@74mph: 1995 Volvo 850 Turbo Wagon
Default

fwiw - over 25k since this mod & it works like a charm.

i recently checked and very little debris were found on the OEM pre-filter screen, no large contaminants and the heavy duty screen i installed is in perfect condition too.
__________________
ECO-DRIVING - advanced driving techniques contributing to sustainable mobility. Links 1 - 2 - 3 - 4 - 5
Bicycles, lots of them, mpg | 05 VW Passat Wagon GLS TDI ~36mpg
SUNRG is offline   Reply With Quote
Old January 22nd, 2010, 08:40   #4
abctdi
Veteran Member
 
abctdi's Avatar
 
Join Date: Mar 2004
Location: ABQ, NM, USA
Default

I have since drilled some holes in the plastic part right in front of the intake tube, just because...
__________________
05 Passat GLS 2.0 PD, UnChained & Steel GPs by VW, 15" steelies, New TB/WP, motor mounts, alt pulley, trans filter, cv boots, TSB #P9/66C8, clear bra & tint, both raxles. Now only driven 1-2 times per week. 123k miles (sold)

DD is a 2012 Kia Optima SX turbo with 274 hp and 269lb-ft@1,750-4,500rpm
abctdi is offline   Reply With Quote
Old January 22nd, 2010, 08:55   #5
traubenberg
Veteran Member
 
traubenberg's Avatar
 
Join Date: Dec 2009
Location: Ville of Liberty
Default

Very nice, I like.
__________________
unchained - 1/15/10; The Autobarn - Mt Prospect
ventectomy - 2/6/10
traubenberg is offline   Reply With Quote
Old January 22nd, 2010, 21:19   #6
DickSilver
Veteran Member
 
Join Date: Jun 2004
Location: Kentucky
Default

I did a simpler mod four years ago that works a well as any. Just remove the duct back to the first elbow that goes down into the OEM screen. Yes, it gets warmer air if the car is in slow traffic, but stays much cleaner and is little fuss. Gone is the scoop that hauls in every piece of trash that flies up into the grille.
__________________
It is useless getting angry at your car: don't let nuthin' whup you that can't talk....
B5.5V TDI, chainless, Rocketchip 2, No EGR, 170K
2012 Golf 2.5, 4 door
DickSilver is offline   Reply With Quote
Old January 23rd, 2010, 17:58   #7
Smokerr
Veteran Member
 
Join Date: Sep 2005
Location: Alaska
Fuel Economy: 43.5/32/28
Default

I did the same thing for a different reason. We had the volcano going off last year and our annual trip down South where it was the worst.

I took the elbow off and had a bulk filter media with me. Idea was to get to a safe spot if needed and just leave as well. Inside engine compartment a lot less crud than road and I could cover the end.

I never put it back as the mileage was the same and the advantage of it not pulling stuff in was obvious. Will see how it looks this spring.
__________________
2005 Passat TDI Wagon
Smokerr is offline   Reply With Quote
Old January 24th, 2010, 09:29   #8
05PassatTDI
Veteran Member
 
Join Date: Oct 2004
Location: Calgary, Alberta
Default

Thanks. Easy and effective. Even I can do this mod. I need to go get some screen material.
__________________
05 Passat TDI Wagon GLS, Stonehenge Gray
05PassatTDI is offline   Reply With Quote
Old January 24th, 2010, 10:27   #9
EYE2
Member
 
Join Date: Oct 2004
Default

Quote:
Originally Posted by DickSilver
I did a simpler mod four years ago that works a well as any. Just remove the duct back to the first elbow that goes down into the OEM screen. Yes, it gets warmer air if the car is in slow traffic, but stays much cleaner and is little fuss. Gone is the scoop that hauls in every piece of trash that flies up into the grille.
Could you please post a picture of what you actually removed and what remains?
EYE2 is offline   Reply With Quote
Old January 25th, 2010, 10:25   #10
DickSilver
Veteran Member
 
Join Date: Jun 2004
Location: Kentucky
Default

I discarded the first piece long ago. Note, the inlet is now inside the engine compartment, not in the grille where is used to scoop in all the bugs & leaves.
I can't figure out how to insert a photo here. Send me a message with your e-mail address and I'll send it to you.
__________________
It is useless getting angry at your car: don't let nuthin' whup you that can't talk....
B5.5V TDI, chainless, Rocketchip 2, No EGR, 170K
2012 Golf 2.5, 4 door
DickSilver is offline   Reply With Quote
Old April 22nd, 2010, 22:57   #11
bogstomper
Veteran Member
 
Join Date: Sep 2003
Location: Woodland (Sac), CA
Fuel Economy: 41/35/32
Default

I just took my mod screen off yesterday and I have to say I notice an increase in responsiveness when accelerating, seems like it wasn't letting enough air through, I did use the exact same screen size as the mod article suggests. It just didn't work out for me after 6 months unfortunately.
__________________
Mine: 2009 Passat Wagon
Previous: '04 Passat GLS TDI RC2, 1998 Jetta TDI RC3
Hers: 2012 Passat SE
Drive like the wind, Straining the limits of machine and man...Neil Peart
bogstomper is offline   Reply With Quote
Old April 28th, 2010, 12:39   #12
CsTDI
Veteran Member
 
Join Date: Oct 2004
Location: Baltimore, Maryland
Fuel Economy: T2: 25-26avg/A6: 49
Default

should there be any issue with removing pieces all the way back to the screen cover as in the first picture? That would seem to be the simplest and make it much easier to access area for filter changes...

If the vehicle is up to highway speeds in warm/hot weather, is there a functional difference in the air temp going into the intake? Presumably more cooler outside air is making its way into the engine compartment but does the coolant system need to work harder? considerably harder?

Finally, I see an only benefits in the dreaded winter in drawing in warmer engine compartment air to mix with fuel rather than the colder outside air resulting in getting the engine up to temp quicker, perhaps longer cool down intervals in winter idling and maybe some positive tweaks in MPGs
__________________
'10 TouaregTDI, Campanella White, '15 JettaTDI, Platinum Gray, '11 GolfTDI, Blue Graphite (buyback), '01 JettaTDI (retired), '05PassatTDI (totaled), '06 TouaregTDI, Campanella White (retired)
CsTDI is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -7. The time now is 17:59.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2020, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2017
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2017, All Rights Reserved
Page generated in 0.20186 seconds with 9 queries
[Output: 106.30 Kb. compressed to 88.87 Kb. by saving 17.43 Kb. (16.40%)]