VW Golf GTi 2.0L 16v MPi 1994 - 97 57-0143-1 Instruction sheet A2054-237-4 Page 1 of 4

PLEASE READ THE INSTRUCTIONS CAREFULLY BEFORE FITTING THE KIT. If you have a problem, however small, call our Technical Department. Tel:- 01925 636950. Fax:- 01925 418948. Monday to Friday 9am - 5pm

1 Detach the intake, breather and vacuum hoses from the air box. Unclip the air temperature sensor and remove it from the air box. Remove the top of the air box. Detach the warm air hose from the air box base, unhook the two small rubber retaining straps in order to remove the lower half of the air box from the vehicle.

2 Fit the bracket supplied to the lower of the two threaded studs on the inner wing using the original nut. Drawings A & B ( also page 5 ).

3 Insert the tube into the standard rubber intake hose and bolt it to the bracket using the M6 nut and spring washer before tightening the intake hose clip. Drawings A & B.

4 Detach the previously removed air temperature sensor from its wiring and fit it to the base of the air filter. Fit the barbed adaptor tube into the new breather pipe supplied, then fit the other end of the barbed adaptor into the smaller hole in the filter base. Drawing B.

5 Insert the new breather hose into the standard breather hose and re-attach the wiring to the temperature sensor before mounting the filter on the inlet pipe. (It may be necessary to remove a section of the wiring binding tape in order to reach the new sensor position.) Drawings B & C.

6 Adjust the filter until the K&N logo is straight before tightening in place. Tighten the clip until the filter just rotates, then give one full turn (360 degrees). No more. Don't overtighten the clips.

7 Remove the small plastic vacuum hose from the inlet manifold and block the pipe with the blanking plug supplied. Drawing C.

8 Cold air system Raise the R H S (offside) of the car, taking the necessary safety precautions.

9 Reposition the horn to provide clearance for the cold air hose. Drawing D.

10 Expand the hose to 16" / 40cm. Position the cold air hose to finish approximately 10cm / 4" from the filter (no nearer). Tie the hose to the slam panel. Drawing C.

11 Feed the hose downwards and position in front of the lower grille Drawings E & F.

12 Tuning. CAT. Cars. No adjustments are required. An increase in fuel mixture may be required if further modifications are carried out.

13 Filter maintenance. Under normal conditions clean and reoil the filter at approx. 40,000 miles / 65,000 Km. Use only K&N cleaner and oil and follow the instructions carefully.

K&N filters are pre-oiled ready to fit.

The advantage's of K&N's cold air intake system. Cooler air being denser, will show positive improvements in power over filter systems that draw hot air from the engine bay. 57-0143-1 Instruction sheet A2054-237-4 Page 2 of 4

This Kit Should Contain IMPORTANT INSTRUCTIONS 1 x Clamp on filter FOR ROUND ENTRY 1 x Metal tube CLAMP ON AIR FILTERS 1 x Cold Air Hose Assembly 1 x Breather hose Gently tighten the hose clip to the point where 1 x Instruction Sheet the filter will just rotate on the pipe or intake 1 x Instruction pack:- flange Reposition the K&N logo straight, then 1 x K&N Window sticker give the clip two turns i.e. 360 , no more. 1 x Filter Maintenance Sheet 1 x Million Mile Warranty FITTING YOUR OWN 57i KIT 1 x Leaflet 1 x Fixing Kit containing:- If not, it is essential that the person fitting the 1 x Barbed Adaptor Tube. kit (e.g. mechanic) carefully follows these 2 x M6 Nuts particular instructions even if he has fitted 1 x M6 Spring washer K&N kits before. This will save you both time 1 x Blanking plug and money. Kits incorrectly fitted may show a 1 x Cable tie (35cm long) loss in performance e.g. the positioning of the 1 x Cable tie (19cm long) essential cold air hose, (flexi expandable and 1 x Cable tie (10cm long) rubber hoses are used). 1 x Hose Clip #60 1 x Metal bracket A final check under the bonnet, by yourself, with the instructions, would seem sensible. 57-0143-1 Drawing A

Standard front intake hose top tube tube filter spac nut

brac suspension Bracket fits to lower detail spring turret threaded section washer SIDE VIEW nut stud

Drawing B Barbed adaptor TOP VIEW Standard intake hose Push sensor into the filter base

sensor suspension turret detail

Remove a section of tape filter to increase the cable length base

Drawing C inlet manifold suspension turret Fit blanking plug to vacuum pipe connection

Push new breather hose into standard breather water hose & filter base hose 4"/10cm no nearer

cold air hose slam panel headlight Tie cold air hose through the hole in the upright bonnet catch under slam panel, using a long plastic tie. 57-0143-1 horn Drawing DDrawing E bracket Release nut & move horn

horn cable

cold air hose small plastic tie Tie cold air hose to the lower grille with a medium grille offside

VIEW FROM UNDER CAR

Drawing F Models without metal pipe, no changes.

Models with metal pipes, need slight alteration, Drawing

Drawing 1 metal pipe

Use long tie FRONT VIEW see drawing 'C'

cold air hose Remove the top nut, front suspension turret release the clamp and move the metal pipe to provide access to the Position the cold air hose Replace both nuts lower nut. as per drawing E when the bracket is fitted. SIDE VIEW lower nut

Drawing 2 Position check for the new flat bracket Drawing 3 suspension turret

bracket

cam belt cover

200mm

bracket