Just thought I'd mention this.

The Cupra PD160 air intake is a great mod, no question. Easier revving, less smoke, especially combined with a free-flowing panel filter.

I've read posts that mentioned removing the deflecting fin in the intake mouth, but didn't bother doing it myself.

Working on the car the other day, I looked through the air intake and could see this fin taking up about half of the intake mouth. What's the use in widening the rest of the airflow passage and neglecting this restrictive part?

Even in the UK's rainy climate, several others have apparently removed this without having rainwater enter the engine. It's supposed to deflect rainwater downwards. I've been told by a gentleman with a heavily-modded Black Magic furby:D that there's a drainage area within the airbox proper to take care of this.

I removed the two torx T20 screws at the top and out it came. Washing it out in the sink, I could see that a lot of flow would be directed downwards.

Dremelled the fin out completely and sanded the interior.

Rinsing it out after the dremelling, I could see that all the airflow would head into the PD160 intake.

Results? You can feel it for sure.

I suppose if you're worried about water ingress, you could just reduce the size of the fin, sand down any rough edges without taking it all out.

Cheers

Bas (BTW I'm really looking forward to meeting up with everyone late August!!)

I have no "mouth" to worry about with mine. Its just the pipe bit sat in open air.

This piece is important to help deflect water and larger debris.

Trust me you do not want water going up there...

Placebo

If water wants to get up there it will, flap or no flap.

As for debris, what do you think the air filter does?

Myself and Josh did this mod when we fitst got our cars, think he even posted pics of it.

Placebo

Its to stop larger debris ending up in the airbox..

keep an eye on your filter if you do this mod, as itll get dirty VERY quickly

On a similar sort of thread I have just had to remove my Cupra intake pipe and replace it with the standard pipe. The problem I am finding is the small rubber pipe to the left of the air inlet pipe has been constantly rubbing and now has a flat spot.

I tried using a pair of pliers to loosen the clip holding the rubber hoses together and rotate the small pipe away from the air inlet but with no success. It seems that the pipe joins may have some sort of seal, is this correct?

I don

I had this problem and I used a couple of plastic wire ties pulled the little pipe away from the Intake pipe...Use one on the little pipe and then put the other one through it and fasten it around a braket....................Sorted

Or use spiral wrap cable protector around the little bleeder.

Could use self amalgamating rubber tape on it first for extra paranoia avoidance.

Oops, meant to mention that too - the larger intake was chaffing the hosepipe off to the side:mad: - couple of wire-ties held it away fine. Did this at the same time.

If you fit the intake, you should do this at the same time - if you haven't - go take a look!!

I did notice an effect from this mod too - placebos don't work on me:rofl: !!

Does the standard intake have this 'flap'?

yes, the air intake is three pieces ahead of the airbox from the "slam panel" (the mouth opening in the "fender" just behind the grille).

The two pieces you change in the PD160 intake mod are the wider flexi rubber hose that connects to the factory airbox (one phillips screw on top) and the hard plastic connector ahead (simple clips - use a wide flat-blade screwdriver).

The part left in the slam panel is the one with the offending fin. Two Torx T20 screws and its a55 is yours:D ....

Wonder what just doing this fin mod with the standard intake would do???? Any air intake system is only as good as its narrowest part.

A pic is worth a million words - do check out Stu's super photo's and step by step guide on his site: fabia-vrs.com

Cheers:thumbup:

Bas

I removed the flap when I fitted the PD160 intake (over a year ago) & have had no problems what so ever.

The only way to remove the flap is to cut it out then?

yes, best way is to dremel tool it out. There's a dremel bit that is tapered and coated like a file - buzzes through ABS plastic in a heartbeat.

alternatively use a drill with a small bit - "chain drill" (make a series of holes outlining the piece to come out) then join up the holes carefully.

File in any case to finish and sand smooth. Be careful not to go through the outer surface of the piece (look from both ends first).

go slow, watch your fingers!

HTH

Bas

restirction is only as good as the narrowest point but, the restriction is also proportional to the length.

since the length is tiny, it is not the same as the whole pipe being that narrow.

As for worrying about crap etc, as said above, thats what the air filter is for.

Not only that but it is fairly high mounted and the crap would still have to navigate a tortuous path the filer through the air box.

As for water ingress and risk of hydraulicing, don't forget there is a high compression turbo charger with an outlet temp pre intercooler of well over 100 degrees. I won't expect you will get much water that isnt vapour by that point.

I would be more worried about solid water droplet damaging the compressor than I would about the water damaging the engine, but both are highly unlikely.

Ok you can remove the flap but why would you need to? The intake on a Fiat coupe 20vt airbox is smaller than a PD160 intake. The coupe airbox is good for 260 bhp plus. Given that the vast majority of fabias are less than 200 bhp why increase the intake area?

I did this mod about 6 months ago and had a rr straight after. same rolling road:

12/11/05

Results prior on indipendant RR 183.7 bhp

06/02/06

Results after dremmeling away 181 bhp dead.

The main difference is the ambient temp on the 1st run was 11 degrees and on the 2nd it was 17 but it was due for it's service on the 1st go and it was about 2,000 post service on the 2nd & it was running tesco diesel on the 1st and bp ultimate diesel on the 2nd.

IIRC torque remains the same.

I have a printout that'll i'll get for it.

Ok you can remove the flap but why would you need to? The intake on a Fiat coupe 20vt airbox is smaller than a PD160 intake. The coupe airbox is good for 260 bhp plus. Given that the vast majority of fabias are less than 200 bhp why increase the intake area?

Totally different engines/fuel and totally different combustion principles/compression ratios.

Turbo Diesels chew through a lot more air than the petrol counterpart.

To confuse things even more - air density drops with higher temps and more humidity (paradoxically). There are tables that show exactly how much, but I left them alone, so I don't get accused of having too much time on my hands again!

My seat-of-the-pants testing was done at 43-45 degree temps, high humidity.

Stands to reason that the diesel needs even more airflow under these conditions than at say 20 degrees.

Ideally the RR testing should be under identical conditions, especially temperature - as for my testing I made sure I wore exactly the same pair of cargo pants both times !!

Cheers:thumbup:

Bas

First sensitive "bit" to get clobbered with water would be the MAF, I'd imagine.

Just don't go boating with your car.

rolling road here too confirmed no gains to behad at all.

I would like to ask how people achieved their performance figures and where the clutch gives out on the remapped cars.

It would seem my unichipping friend has managed to get a fabia vrs to 189bhp and 312lbft!!!!!

I can't believe it.

Not going to be doing it on my car until warranty is out, but have to say I am impressed at what is to come!

Any water in the engine is bad news, it only takes around 500cc's of water to seize the engine and that means big bills and it will easily pick that up in the flash.

Seen it done may times and not only in flood water. Get a deep enough puddle at the side of the road and when a car hits it you get a bow wave come up and it sucks it in.

Totally different engines/fuel and totally different combustion principles/compression ratios.

Turbo Diesels chew through a lot more air than the petrol counterpart.

Different fuels yes but a they both burn fuel in air to give energy. Diesels generally run with far more air than they need to burn the fuel. This is why increasing the fuelling gives sizable power gains- there is already plenty of air to accomodate the extra fuel. Which begs the question why increase the intake area massively when there is already enough air getting in?