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Forum VW Model-Specific Forums Golf V & Jetta V cut engine cover *DIY how to to fit with an aftermarket intake

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Thread: *DIY how to cut engine cover to fit with an aftermarket intake
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RruizGTI *DIY how to cut engine cover to fit with an aftermarket intake 12-03-2007 11:38 PM #1
Member
plenty of people on these forums have cut their engine covers to fit with an aftermarket intake. when it was time to do mine i decided to
try and make a DIY while i was at it. so here it is.
This document is for informational purposes only. Any vehicle modifications should be done by a certified VW mechanic. Neither the author
nor this site will be held liable for actions taken resulting from the information set forth herein.

Join Date: May 2nd, 2007 STEP 1: first of you have to buy and install an aftermarket intake. i was lucky enough to be given the intake you see here. (Neuspeed)
Location: Rancho Cucamonga
Posts: 379
Vehicles: 2007/VW/MKV GTI 6MT

STEP 2: use this thread to see how to take your engine cover apart. http://forums.vwvortex.com/zerothread?id=2547554
easy, only 8 screws. this is what it will look like when its taken apart.

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STEP 3: here is the bottom half of the cover. the white lines show where you will be cutting. careful not to cut into the mounting points

STEP 4: once you cut at those lines i found it easier to cut here also.

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and here

it will make it easier to install your modified engine cover withough having to un-install your current intake. it should look like this after all
of these cuts are made.

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STEP 5: here is the top half of the engine cover, the white lines show where you will be cutting.

top cover cut

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top cover cut bottom view

now your basically done, the top cover may need some additional cutting. i forgot to take pictures of it. but in the picture above you can
see that i pretty much made the top half of the cover a flat surface. thats what i mean by additional cutting.
heres two views of the cover completely cut and put back together. only now instead of 8 screws holding the cover together theres 6. 6
screws is more than enough to hold the cover together so no worries there.

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now for the installed pix

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***before installing your freshly cut engine cover. make sure you re-connect your MAF sensor. now your done. hope this is helpful to
anyone looking to modify there engine cover. shoot me a PM if you have any questions. oh yeah dont forget to have some of these to
celebrate your accomplishment . thanks for looking

Modified by tekhfloksk88r at 9:40 PM 12-3-2007

Last edited by RruizGTI; 08-30-2011 at 05:17 PM.

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00:13/01:18

RiverCityRejects Re: *DIY how to cut engine cover to fit with an aftermarket intake 12-03-2007 11:42 PM #2
Member
(tekhfloksk88r)
Join Date: Oct 2nd, 2006 good work
Posts: 282

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ENRGZR Re: *DIY how to cut engine cover to fit with an aftermarket intake 12-03-2007 11:44 PM #3
Member
(RiverCityRejects)
looks good

Join Date: Oct 11th, 2006

Location: Lacey, Wa
Posts: 2,592
Vehicles: 91 Golf, 99.5 Jetta, 07
Rabbit, 13 Focus ST

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XBL/PS3: ENRGZR
AKeuro / CCA Motorsport / Air by Santi / Fifteen52 / C2 / Trac Wrap

Originally Posted by 5P4RK4

A dozen 1000 miles is 120,000 not 12000, thats 1.2 1000 miles.
edit. wow I fail. Im going to leave that there to remind myself not to do math.

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drpsycher Re: *DIY how to cut engine cover to fit with an aftermarket intake 12-03-2007 11:44 PM #4
Member
(tekhfloksk88r)
freaking awesome man...

thanks for helping us all out

[IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG]
[IMG]http://*****************.com/smile/emthup.gif[/IMG]
Join Date: May 23rd, 2005
Posts: 860

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RruizGTI Re: *DIY how to cut engine cover to fit with an aftermarket intake 12-03-2007 11:53 PM #5
Member
(RiverCityRejects)
thanks for all the positive feedback guys. hopefully this gets stickied into the DIY thread

Join Date: May 2nd, 2007

Location: Rancho Cucamonga
Posts: 379
Vehicles: 2007/VW/MKV GTI 6MT

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JODZ 12-04-2007 12:31 AM #6

Member
What did you do the cutting with?

Join Date: Feb 16th, 1999

Location: Bayonne, NJ
Posts: 1,002
Vehicles: 2017 White Golf R DSG
DCC/DAP

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RruizGTI Re: (JODZ) 12-04-2007 12:37 AM #7

Member

Join Date: May 2nd, 2007

Location: Rancho Cucamonga
Posts: 379
Vehicles: 2007/VW/MKV GTI 6MT

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this

haha forgot to throw that in there. i also filed the edges after i was done cutting them so they would be smooth.
im sure a jigsaw would do fine also. that and a screw driver is all you pretty much need to do this mod.

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ShutItDown Re: (tekhfloksk88r) 12-04-2007 08:53 AM #8

Member
looks like saw dust all over your internals.

Join Date: Jun 14th, 2007

Location: Kansas City, Missouri
Posts: 1,836
Vehicles: 2006 Subaru Baja
Turbo

Sold: 1993 240sx SR20DET

Sold: 2004 JCW Mini Cooper S
Sold: 2007 Volkswagen GTI APR S2+
Now: 2006 Subaru Baja Turbo
WTB: MKII GTI

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RruizGTI Re: (ShutItDown) 12-04-2007 08:20 PM #9

Member
its dirt and dust that has accumilated over time. what do you guys use to keep your engine bay nice and clean?

Join Date: May 2nd, 2007

Location: Rancho Cucamonga
Posts: 379
Vehicles: 2007/VW/MKV GTI 6MT

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david8814 12-04-2007 08:40 PM #10

Member
Join Date: Aug 14th, 2007 I haven't had to clean my VW's bay yet, but I'd just use a power washer in my truck bay. Set it to lowest setting (i.e. wash your kid's a**
Posts: 652 with it gentle), and hose away. You might want to put a bag over your filter though so it doesn't get deluged.

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TPizzle Re: *DIY how to cut engine cover to fit with an aftermarket intake 12-04-2007 08:42 PM #11
Member
(tekhfloksk88r)
Cool [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG]

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Join Date: Jan 14th, 2007

Posts: 1,426

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veedub888 Re: *DIY how to cut engine cover to fit with an aftermarket intake 04-22-2008 02:19 AM #12
Semi-n00b
(RruizGTI)
Has anyone done this for a EVOMS Cold air intake?

Join Date: Apr 14th, 2008

Posts: 12

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Ricky Bobby Re: *DIY how to cut engine cover to fit with an aftermarket intake 04-22-2008 01:09 PM #13
Member
(veedub888)
Join Date: Sep 29th, 2005 nice work!
Location: NJ
Posts: 2,831
Vehicles: BMW X5 5MT, E70 X5
35D, Triumph Thunderbird 1700

Originally Posted by Silly_me

Did you have to use a doll to show the jury where Matthias Mueller touched you?

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-Rooster- Re: *DIY how to cut engine cover to fit with an aftermarket intake (Ricky 04-22-2008 03:51 PM #14
Member
Bobby)
awesome [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG]

Join Date: Mar 28th, 2008

Location: CT
Posts: 769
Vehicles: 06 S4 Avant 6MT/12 S4
6MT (sold)/07 GTI 6MT (sold)

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knoxvillezzz Re: *DIY how to cut engine cover to fit with an aftermarket intake 07-27-2008 11:12 AM #15
Member
(veedub888)

Quote, originally posted by veedub888 »

Has anyone done this for a EVOMS Cold air intake?

Join Date: Apr 26th, 2008

Yup same question here..
Location: Massachusetts
Posts: 771
Vehicles: 2007 GTI MKV DSG
(SOLD), 2012 VW GLI

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VwGTIKid Re: *DIY how to cut engine cover to fit with an aftermarket intake 07-27-2008 02:05 PM #16
Member
(knoxvillezzz)

Quote, originally posted by knoxvillezzz »

Yup same question here..

Join Date: Apr 30th, 2006

Posts: 1,872
yup x3 wondering if this would work with evo ms as well

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pch0mey 08-07-2008 03:31 PM #17

Member
Join Date: Jun 24th, 2008 Awesome guide. I just installed my Neupseed P-Flo last night and this guide was a perfect step by step solution to cutting the perfect fit
Posts: 534 engine cover.

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GTiMK5_TJ Re: (pch0mey) 01-07-2009 03:16 PM #18

Awaiting Email Confirmation

Quote, originally posted by pch0mey »

Awesome guide. I just installed my Neupseed P-Flo last night and this guide was a perfect step by step solution to cutting the perfect fit
engine cover.

Join Date: Jun 29th, 2008

Posts: 458 x2 agreed. good way to guide you in.... i modified the sections i cut, and sanded the edges down to have that smooth and even finish on
the ends.
Kudos and

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SchneidyP845 Re: (GTiMK5_TJ) 01-07-2009 11:58 PM #19

Member
"***before installing your freshly cut engine cover. make sure you disconnect your MAF sensor."
Did you mean, connect the MAF? I will be doing this in the next day or 2, just waiting for the p-flow.

Join Date: Jul 1st, 2008

Location: OH
Posts: 986

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blackgolf2.slow 08-29-2011 07:49 PM #20

Member

Originally Posted by SchneidyP845

"***before installing your freshly cut engine cover. make sure you disconnect your MAF sensor."
Did you mean, connect the MAF? I will be doing this in the next day or 2, just waiting for the p-flow.
Join Date: May 12th, 2010
Location: Winnipeg Manitoba
Posts: 391 I was wondering this too, i have the autotech cai and will be doing this tonight
Vehicles: 2007 gti bmp 6spd mt

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RruizGTI 08-30-2011 05:16 PM #21

Member

Originally Posted by blackgolf2.slow

I was wondering this too, i have the autotech cai and will be doing this tonight

Join Date: May 2nd, 2007

Location: Rancho Cucamonga your going to want to re-connect your MAF sorry for the confusement. its going to be hard to reach under the cover once you re-install it.
Posts: 379 it'll self explanitory once you get this far into the process.
Vehicles: 2007/VW/MKV GTI 6MT

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honkylips 08-30-2011 05:36 PM #22

Junior Member
Join Date: Nov 2nd, 2009 Been looking for a useful DIY for this. Thank you.
Posts: 87
Vehicles: Black MKV Jetta

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Katia_Qberry 07-29-2012 02:32 PM #23

Semi-n00b
Join Date: Jun 21st, 2011 Awesome!! Thank youuuu!!
Location: Fair Hill MD
Posts: 14
I know this is an older thread, but my EOS also has the FSI. I installed a EuroSport CAI last weekend at Waterfest, and I need to do
Vehicles: 2008 EOS 2.0T FSI something about an engine cover before H2Oi

: DUBL DEE DUB :

"Its not turbo lag.. its foreplay"

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The Gerb 07-31-2012 09:05 PM #24

Member
i
am gonna try and do this on the weekend.

Join Date: Mar 6th, 2012

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Location: Roanoke, VA
Posts: 700
Vehicles: 2006 GLI, 87 GTI
(sold), 98 Jetta GLX (sold), 72 Super
Beetle chopped (sold)

My username used to be Slow MK3. But ive upgraded to a MK5 GLI so i changed my name.

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b--ryan 03-02-2013 07:46 AM #25

Member
Join Date: May 13th, 2008 great DYI!
Location: G-ville sc
Posts: 245
Vehicles: 1996 harlequin #139

2008 Audi A3

1996 H A R L EQUIN

Harlequin #139 Blue Base

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