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Installed/How-To: APR/Carbonio Stage 1 & 2 Intake System

56K views 67 replies 35 participants last post by  resilientsoma  
#1 ·
Given that the 2011 GTIs don't have the "noise pipe", the engine noise is very muffled compared to the 2010 GTIs. Clearly this is an excellent excuse to call APR and order their intake system. Especially with a turbo, intakes just sound downright cool.

So now that I finally have 500 miles on my car, I felt like I could start modding the car and not feel too guilty about it.

Tools that you'll need:



STAGE 1 INSTALLATION:

Here it is, stock and boring:

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My install is slightly different than how APR recommends, but I found this much easier. First step is to remove the top half of the airbox. It's about 8 or 10 phillips screws holding the top to the bottom of the airbox. Be sure to unplug the MAF and also remove the hose clamp that holds the MAF to the turbo inlet tube.

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With the top half gone, now you can easily remove the two T25 screws holding the air inlet scoop. APR lists these as T20, but they are in fact T25.

The next thing it do is remove the bolt that holds the bottom half of the airbox to the car. This is a 5mm allen:

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Now you can pull up on the bottom half of the airbox to remove it. Be firm, but not forceful, as the airbox sits on two studs which are pressed into rubber grommets in the bottom of the airbox. Once the airbox is free, you'll see a drainage tube that goes from the bottom front right section of the airbox down into the bumper:

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This isn't attached to anything, so just carefully keep pulling the airbox out of the car and it will soon be free.

Now it's time to assemble the Carbonio airbox. This is rather simple, just make sure to use the rubber washers provided in the kit, and make sure the rubber side is touching the carbon fiber.

The hardest part is getting the filter onto the carbonio air inlet. To do this, I lubricated the air filter connection with some general purpose cleaner and forcefully pushed and pushed until the filter went over the air inlet connection. I removed the hose clamp all together to make sure I could get enough stretch in the rubber:

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Once you have made the connection, fully unscrew the hose clamp and place it around the filter connection and tighten it down. Be careful not to make it too tight - that is not necessary, and you don't want to crack the carbon fiber.

Next remove the MAF from the airbox lid (two phillips screws) and attach the applied silicone coupler. Again I left the hose clamps completely off so I could have more room to stretch, and I also moistened it with some all purpose cleaner so it would slide on easily.

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Now you can assemble the Carbonio airbox (it's really not complicated, so I didn't document it), and install it into the car:

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I kept it like this for a couple of days so I could see how much of am improvement the Stage 1 makes over stock. The sound increase is not drastic, but it's noticeable and provides a nice deep growl on acceleration as well as increased turbo noise. Power wise I instantly felt it, especially a bump in torque down low. Absolutely awesome - just the right amount of noise, not obnoxious, and a good power bump.

STAGE 2 INSTALLATION:

Now that I have driven around with the Stage 1 for a while, I wanted to see how much of a difference the Stage 2 would make, both in terms of power and in terms of looks.

APR states that this should only take about 20 minutes to install, but I found it a little trickier than the airbox install. This is mostly because it's a tight fit and it takes a while to tweak the pipe and make the fitment correct.

Get your handy hose clamp pliers and remove the section post MAF:

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With this section removed, I found it was much easier to remove the T30 bolt (APR incorrectly lists this as a T25 in the instructions) that secures the inlet pipe.

Now use the pliers again and remove the hose clamp that holds the inlet pipe to the turbo coupler. This is a tight fit, so it takes some contorting to get the pliers down there. Once that is removed, slide the pipe up and remove the breather hose:

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This is an odd connection (first time for me seeing one of these connections), and I found the easiest way to remove it was to slide a small flat head screwdriver under each side, as that "unhooked" it and it could be removed.

The inlet pipes side by side:

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As you can see, the location of the breather hose is different on the two pipes. I noticed that with the Carbonio pipe installed, the breather hose is significantly closer to the heatshield for the downpipe. I called APR and asked about this and they said that that shield doesn't get hot enough to warrant an issue, however I don't know why the hose connection is in a different location.

Now to install the Carbonio pipe, just use the provided hose clamps (not the spring-loaded clamps that were originally used - these will crush the carbon fiber pipe), and as I said before, you don't have to tighten these super tight.

Breather hose connection:

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I noticed that the pipe was a little close to the brake fluid reservoir and the brake line, so I propped something between the pipe and the brake fluid reservoir, and then loosened the turbo side hose clamp and then pushed the pipe further into the turbo side.

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Now you can tighten the hose clamps and the provided 10mm bolt with rubber washer that mounts the pipe to the rear of the engine (replaces the T30 bolt stock). You should have some room between the reservior and the pipe if you followed the above instructions properly:

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If the pipe is too close, it will hit when you start the engine, and you'll be able to feel it through the pedals. If so, loosen the clamps and bolt and adjust it for more space.

When aligning the turbo coupling hose clamp, angle it as follows so that you can easily reach down and loosen/tighten the clamp with your 8mm nutdriver (this won't apply if you have a 2010 with the noisepipe):

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And for the final product:

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As you can see, it looks much better than factory, and better than just the stage 1. There was another slight increase in sound (I could hear the DV sound more with the second pipe installed), but I couldn't notice a power bump as I did when installing the stage 1. So if you are just looking for power, you only need the stage 1. If you want a little more sound and a nicer looking engine bay, spring for the stage 2.

Hope this helps.

- Anthony
 
#9 ·
Yes. You unplug the MAF. Just be careful with the MAF sensor.. they are fragile and could crap out on you.

I've added my carbonio/removed my stock intake in about 10 minutes. It's the easiest install you could probably ever do!
 
#16 ·
Additional Clearance Available...

Anthony@VMG,

You can gain additional clearance between the Carbonio Stage 2 pipe the brake fluid reservoir and the battery box by bolting the mid-pipe brace to the FRONT SIDE of the engine bracket instead of the back side.

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Doing so increases the clearance at the brake reservoir:

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And clearance at the battery box (white towel shows gap):

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#18 ·
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This isn't attached to anything, so just carefully keep pulling the airbox out of the car and it will soon be free.


So did you just completely remove this part? i was confused because when i replaced my intake, i could not figure out why it was there. It has a plug at the end and totally serves as a dummy. what confused me is why it was there in the first place. I realize the purpose of this pipe on the '10 tsi and '09 tsi, however on my '11, it connects no where. i am somewhat fearful that this is suppost to go somewhere. Basically my question is, am i ok without this pipe?
 
#19 ·
So did you just completely remove this part? i was confused because when i replaced my intake, i could not figure out why it was there. It has a plug at the end and totally serves as a dummy. what confused me is why it was there in the first place. I realize the purpose of this pipe on the '10 tsi and '09 tsi, however on my '11, it connects no where. i am somewhat fearful that this is suppost to go somewhere. Basically my question is, am i ok without this pipe?
It is a drainage pipe incase water gets in the airbox. It is not used with aftermarket intakes.
 
#20 ·
oh i see. well thank you that helps. so 2011 gti's dont use a secondary air filter?
 
#26 ·
They will make your life 100x easier. With a pair of pliers, you risk a chance of the spring hose clamps flying off of the pliers, and that can be very dangerous.

Shipping is free from snap-on's website as well.
 
#33 ·
I understand where you're coming from, I paid all that money it should be "perfect".

Now, on the other hand is it really worth the time and money to ship it back, when according to APR is purely cosmetic? On a part that can't even be seen no less.

Not trying to be a PITA or anything, just a little debate.
 
#34 ·
Anthony - have you noticed a decrease in MPG's since installing your Carbonio? I ask because my mileage seems to have decreased after installing mine. I could be mistaken and the winter weather + short drive to work is to blame. I haven't really gotten to take it for a long drive since I got the Carbonio installed. It could just be all in my head, I don't have any dash lights or anything so I'm fairly certain it's installed correctly (dont have VAGCOM to check for codes). It's not like it was difficult to install, didn't drop the MAF or anything.

Per Fuelly I filled up 12.83 gallons so I probably still had 40-60mi til 0, I got 283 mi from 12/2/10 to 01/3/11. So I would've gotten 320-340mi that tank had I run it dry. I installed the intake on 12/14/10 so somewhere in the middle of that tank I'd imagine. My commute to work is only about 7mi each way and it's highway.
 
#38 ·
sorry to bring this thread back from the dead, but I'm installing my carbonio stage 1 right now and cant, for the life of me, get the maf sensor unplugged. i DONT want to damage it. any trick?
 
#40 ·
after much headache, i just got a flathead and lightly pryed up on the sensor connector and it came off with ease. now i just need to know how in the hell you unscrew torx screw with a phillips screwdriver per the apr directions....
 
#41 ·
forget the above. i cant get the damn apr filter on the carbon fiber piece. ive tried wd-40 and bike chain grease. i cannot get that filter over the pipe. ive also tried taking needle nose pliers and trying to stretch the rubber on the filter. any suggestions?
 
#43 ·
I

I ended up using a knife to cut the first three threads of rubber on the inside if the filter. I did this for about a fourth if the circumference. Then I applied some dish soap to the inside and started to push. Finally got it on. I think it should be free from leaks cause that thing is on there tight. Almost twisted the element trying to get it on.

then I realized how much of an idiot I am because I have a cbfa engine and didn't but a breather valve. Looks like I'm off to aptuning this morning...