 | Home > Maintenance & Modifications > Air box mod and decat |
 
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| Yannis Member Since: 02 Feb 2015 Location: Oxfordshire / Milan Posts: 408   
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Scroll up a few posts on page 10. Should still be some pictures there.
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13th Jan 2023 6:20am |
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| roel Member Since: 08 Aug 2009 Location: Lelystad Posts: 2039  
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The air goes through a piece off pipe along the btm off the airbox. In the photo the top half is cut off.
I didn't do that I just cut the last inch off as there is a lip that should catch the water what should go to the outside off the pipe due to the propeller. Roel 1984 90 2.5 na Diesel - RR V8 (1994-2001) 1997 Camel Trophy Discovery 300TDI (2001-2009) 2005 G4 Discovery III 4.4 V8 (2008-2018) It's gone but it still hurts. 2003 90 Td5 (2009-now) |
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13th Jan 2023 6:20pm |
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| nitram17 Member Since: 08 Jun 2014 Location: newcastle Posts: 2261 |
im a little confused
 do you have any pics? as it sounds like you have just cut off one inch of the pipe top at the proximal end.......Will that have much of an effect? |
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13th Jan 2023 9:18pm |
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| roel Member Since: 08 Aug 2009 Location: Lelystad Posts: 2039
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I took the propeller out and took the inside lip off. That lips is about 10 mm, I think so the diameter got 20 mm bigger.
I am not sure about how effective that is but as I sealed the airbox for off-roading, there is no need to catch the water. I can't go anywhere to the outside. Roel 1984 90 2.5 na Diesel - RR V8 (1994-2001) 1997 Camel Trophy Discovery 300TDI (2001-2009) 2005 G4 Discovery III 4.4 V8 (2008-2018) It's gone but it still hurts. 2003 90 Td5 (2009-now) |
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14th Jan 2023 5:56pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20338
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Photo courtesy of Yannis which I have image edited.
I’m unsure what the yellow part is with the screw installed is, but the part I have surrounded in green is the part that is cut out, this is after the job has been done. The black plastic in the blue area is what would be removed, the photo is from after the job was competed.**  Click image to enlarge $W33T $0U7H3RN $UG4R 🇬🇧🏴🏴🏴🇮🇪🇺🇸⛽️🛢️⚙️🧰💪 |
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12th Jun 2024 6:14pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 513
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Not sure if this will help anyone but as I've got the bits lying around I'll post the pictures.. Then along with what's been said about how to mod the intake it might help someone..
First picture is basically the intake system complete Click image to enlarge Next the fixed vanes that you remove by depressing two little catches.. And pulling it out.. You should be able to see that in this picture Click image to enlarge And a picture looking into the intake pipe where those vanes sit.. Also showing the water drain arrangement.. And when you remove that inner tube then you could cut into the drain hole.. Hence the yellow disc in the picture posted above.. Its been cut into and had to be sealed up again.. Hope that helps along with the explication above Click image to enlarge |
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13th Jun 2024 11:57am |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20338
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Very useful, if I remember rightly the rain separator is a bit more tricky to remove but worth removing.
Mainly avid injuring yourself on plastic pieces… Mine has sealed up pipework but if I was to do the job again I’d fit new aftermarket pipework, at the time there wasn’t many options on the market. Currently I’d rather not have to go to the trouble of removing the Snorkel just to do that, especially the bonded upper bracket. But removal of the rain separator and airbox section is worth doing, I’ve never had any issues with damp air filters or and nuisance DTC’s in years. I have never had a problem at all. $W33T $0U7H3RN $UG4R 🇬🇧🏴🏴🏴🇮🇪🇺🇸⛽️🛢️⚙️🧰💪 |
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13th Jun 2024 12:06pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 513
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I wish I'd known about all these mods before I spent money on the Ali sport intake👍🤣..
By rain separator I'm assuming that's what I'm calling vanes.... If so they come out easy enough.. Couple little projections need pressing in to release it.. Its the inner pipe that when cut away exposes the drain in the air box.. Another pic.. Click image to enlarge |
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13th Jun 2024 12:22pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 513
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Just as an aside but vaguely related🤣.. I eventually got round to making up some adaptors and bits to fit one of those centrifugal air cleaners to the top of my snorkel..
Read posts about them on here and with a pending trip to Morocco at end of year I thought I'd give it a go🤔👍 Click image to enlarge |
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13th Jun 2024 12:29pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17365 
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You will have a much more satisfactory solution with the Allisport intake and filter than you will ever get with the factory tat, and the engine will breathe more freely. The "airbox mod" will result in some improvement, but the Allisport will be an order of magnitude greater. |
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13th Jun 2024 12:34pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 513
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Well blackwolf that's what I'd hoped for.. And I had maf and scope data on air flow before I fitted the alisport system.. The system I got was the air box that takes the intake in the same location as the standard intake ducting.. Its supplied with a wing adapter and takes 76mm inlet trunking connecting the air box..
I have the 2.2tdci with abs and the connection to the wing adapter isn't a straight fit, the pipe comes away from it in a downward direction very quickly to avoid pipework.. So that may be an issue... Anyway I checked the air flow and it was down by about 2.5gms/s after I fitted the alisport system.. That was confirmed by the scope all be it in a frequency readout.. I put in an ITG foam filter and that lifted the intake up by about 1g/s but still not at the 16g/s I was recording at tick over before I fitted the alisport system.. Its driving just as it did before.. No better no worse.. But the air flow figures are marginally down.. I was surprised and it's still work in progress to run some more tests.. The fitting of that centrifugal air cleaner hasn't altered the maf intake figure.. I had expected to see a small reduction.. I think I posted on here at the time about what I found.. So up to now I don't think the alisport intake is giving a better air flow than the standard trunking... And it was well sealed with non setting mastic.. |
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13th Jun 2024 1:03pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17365
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Hmm, that's both unexpected and disappointing.
I have a Nugget filter box with a Nakatanega top-entry RAI with centrifugal pre-cleaner. The pipework is around 4" diameter and the difference from the original but modded airbox and LR duct is like night and day. |
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13th Jun 2024 2:06pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 513
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Yep that's what I thought.. And as I said the only part that gave rise for a bit concern was the connection at their wing adapter.. With abs pipework and the wing mounted aerial the pipe is a far from easy fit..
I will when I can get round to disconnecting at the filter box end and see if it is the pipework to the wing connection that is causing the reduced flow.. If it is I'll likely make my own winh adapter for the 90 mm hose and try that.. But not really what I had wanted to be doing after splashing out on their intake system... Very nice looking though it is.. I think it was one of your threads that led me down the pre cleaner route.. 👍 I am happy with that🤣 |
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13th Jun 2024 2:53pm |
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