THanks for the write up.
I didn't see a post for the 2.5L Engine Cover so here goes....
Tools You'll need:
Torx 15 Driver
This image basically shows the points where the cover is attached:
First Step is to remove the torx screws holding the cover to the air intake:
Next Remove the sensor connection:
Use the pliers to release the hose:
Now to the cover itself:
You will need to use some pressure to pull the cover from the mounts.
I pulled up on the lower left corner and it will sort of pop free, like pulling
a cork out of a bottle. Repeat this with the other corners.
Finally you will need to wiggle the cover free from the engine compartment.
There is a down-tube on the back of the cover that requires some work to wiggle it free.
This Picture shows the back of the cover:
To remove the air filter simply remove the screws on the back of the engine cover.
The screws are numbered 1-5 so I removed them in that order
The filter cover then can be opened as so:
Modified by texallen01 at 10:43 AM 3-9-2006
Quote, originally posted by soundguydave » For the life of me, that sensor will not come off. Also, it looks like I have have a nother sensor on the air intake thats not in your picture.
x2 ... hopefully someone can provide some tips. Pull straight off or need a flathead somewhere?
On TDIs, installing a K&N filter is a no-no; I think it's because it fouls up the MAF sensor with oily residue. Could that be a concern on the 2.5 and it's post-air filter sensors? Just curious.
2006 VW Jetta TDI - 187,000 miles. Amber LED taillights; Hella Dynabeams; Dieselgeek skidplate. Running fine on Mobil TDT oil. Waiting for the R.
just finished installing my K&N... thank you for the how-to, although, as pointed out earlier, there's an extra sensor on many of our engines that yours doesnt have... just at the bend in the air intake (right behind the right side torx screw).
to remove this sensor, it's easiest to spin the lower body of the sensor around (make the VW/Audi symbol face downward) and use a flat-head screwdriver to pull up gently on the clip. The housing should separate easily from the gray sensor body.
total time was about 30 min to install, though 15 of that was trying to get the hose clamp back on with only a leatherman, rather than a pair of channel-locks. i had to bike down to autozone and pick up a set of proper pliers to finish it.
The best way to remove the sensors is to pry gently on the tabs with the notch in them. This releases a catch and they pull right off. Once off you can see the catch on the inside of the connector.
The K&N filter really improved throttle response and I think the power is better as well. The engine noise is slightly more throaty now as well. It will be interesting to see how the gas mileage changes as well.
The air flow was so good that the engine had to relearn the idle setting taking about 20 seconds to settle down to a normal idle. This was also apparent on the other RPM ranges as driving it seemed to be adjusting as I drove. After running through the gears for 10 minutes city driving it seemed to have the new flows learned though.
Today i tried to remove the engine cover and I noticed that the small tab that is depressed to remove it was cracked and barely holding, of course, I touched it and just fell off, now I cannot get the sensor detached, is it possible to buy the cap? the part where the fingers are holding it in the picture I must say...
Modified by jtovarrr at 7:51 PM 2-6-2008
I gave up on the connector. Layed down a blanket over the drivers fender, then flipped gently over the engine cover and worked on it in the engine bay...again gently, no pulling wires. Not recommended,
His: 07 MK5 CW 4dr,2.5L std: Rabbit bump vinyls, 18" RML Snowflakes w/ 225/40/18 Falken 912's, K&N airfilter
Hers: 08 MK5 Salsa Jetta 4dr, 2.5L Tiptronic: Hankook Ventus V4 ES on 16" MUGELLO's
Daughter's: 98 MK3 GTi, 2dr, 2.0L std: 16" Borbet T's, BFI chip, 60/40 cupkit, 2.5" exhaust w/Borla muffler