injen SP3016 User manual

Part number SP3016
99.5 -2003 Jetta/Golf with ALH
TDI turbo diesel engine
2004-2005.5 Jetta/Golf PD BEW
TDI Turbo diesel engine
1- 2 - pc. intake pipes
1- 2.5” Injen filter (#1012)
1- 2.75” straight hose (#3043)
1- TT intake hose (#3046)
4- 040 Clamps (#4003)
2- M4 button head screw (#6072)
1- M6 vibra-mount (#6020)
1- M6 flange nuts (#6002)
1- M6 washers (#6010)
1- 11/2” X 1/4 alum. coupler
1- 6”-6mm vac hose
1- 4 page instruction
Note: All parts and accessories now
sold on-line at :
“injenonline.com”
Congratulations! You have just purchased the best engineered,
dyno-proven cold air intake system available.
Please check the contents of this box immediately.
Report any defective or missing parts to the Authorized Injen
Technology dealer you purchased this product from.
Before installing any parts of this system, please read the instructions
thoroughly. If you have any questions regarding installation please
contact the dealer you purchased this product from.
Installation DOES require some mechanical skills. A qualified
mechanic is always recommended.
*Do not attempt to install the intake system while the engine is hot.
The installation may require removal of radiator fluid line that may
be hot.
Injen Technology offers a limited lifetime warranty to the original
purchaser against defects in materials and workmanship. Warranty
claims must be handled through the dealer from which the item was
purchased.
Injen Technology 285 Pioneer Place Pomona, CA 91768 USA
Please check the contents of this box immediately.
Note: This intake system was Dyno-tested with an Injen filter and
Injen parts. The use of any other filter or part will void the
warranty and CARB exemption number.
Parts and accessories are available on line at “Injenonline.com
Note: Injen strongly recommends that this system be installed by a
professional mechanic. MR Technology
“The World’s First Tuned air Intake System!”
Factory safe air/fuel ratio’s for Optimum performance
Patent# 7,359,795
Now equipped with “Air Fusion” Patent pending
“At Injen Technology, we didn’t copy the step down process, we
invented it!”
Figure 1 Figure 2
Warning: Manufactures attempting to duplicate Injen’s
patented process will now face legal action.
MR Technology Step down process:
1- Calibration Method for Air Intake Tracts for Internal Combustion Engines.
Covered under Patent# 7,359,795
2- Calibration Device for Air Intake Tracts for Internal Combustion Engines.
Published and patent pending
3- Calibration Method and Device for Air Intake Tracts having Air Fusion Inserts
Published and patent pending

Note the original position of the two horns in the bumper
cavity. Use a 13mm socket and rachet to loosen nuts on
horns and relocate horn #1 with horn #2.
Figure A: use a 10mm socket and rachet and tighten
the two 10mm bolts on the air box cleaner.
Figure B:Use a T20 torx driver to loosen two torx
screws from MAF sensor to air box cleaner
Figure A: Remove four 8mm bolts with a 8mm driver
Figure B: Pull the headlight forward to unplug the
headlight harness and then remove entire headlight
assembly
Figure A: Locate the two plastic rivets and then
remove the the plastic frame behind the headlight.
This frame will no longer be re-used in this installa-
tion.
You now have access to the five torx bolts with the
grill removed. Use a T25 torx driver to remove the five
torx bolts
Figure A: There are 11 T20 torx bolts on the bottom
side of the bumper that will need to be removed in
order to remove the front bumper. Figure B: You may
now remove the front bumper by pulling forward.
Stock box shown in this picture Figure A: On the back side of the grill is the unlocki
ng clip for the hoodlatch. This clip need to be lifted in
order to remove the latch from the hindge. Figure B:
Hood latch is disconnected
Lets start off by first removing the front bumper. Lift
up on the front grill and pull towards you to unlatch
the grill from the bumper. This will give you access to
the hood latch that will need to be unhooked.
Figure A: Pull firmly on the lower outer grill to remove
it to acess one torx bolt and repeat for the opposite
side. Figure B: turn the steering inwards to access
four t20 torx bolts on the plastic fender liner.
Figure A: Behind the headlight, there is a two piece
plastic panel that you will remove four phillips screw
from. Figure B: Once the four screws are removed,
pull the entire two piece panel out.
Figure A: Unbolt 13mm nut on horn #2 and remount
horn #1 onto horn #2. Figure B: Horn #1 is now
mounted onto horn #2. This will allow room for place-
ment of the Injen filter
Figure 3 Figure 4 Figure 5
Figure 6 Figure 7
Figure 9 Figure 11
Figure 12 Figure 13
Page 2 of Part# SP3072
AB
ABA
Figure 8
B
B
A
AB A
Figure 10
Horn # 1
Horn # 2
Horn # 1
Horn # 2
Horn # 2
Horn # 1
AB
13mm bolt
Figure 14
A
B

Place the 2.50” filter onto the 2.50” aluminum tube.
adjust the pipe and filter for best possible fitment..
NOTE: horn #1 was relocated to make room for filter in
figure 12
Figure A: Place the short end of the intake pipe and
insert it into the TT silicone intake hose. Figure B:
Now place the long end of the intake tube into the
2.75” straight hose previuosly installed in figure 19.
Position of the silicone TT hose in place. Place a 040
clamp onto the end of the silicone as seen in the photo Place the smaller aluiminum intake tube into the sili-
cone hose and make sure you add a 040 clamp onto
the silicone intake tube.
Mount the vibramount on to the factory bracket already
mounted on the drivers side shock tower. Vibramount
shown mounted on shocktower.
Place the silicone TT intake hose into the same path
way the factory air duct once was. Make sure the
bigger end of the silicone is on the top side.
Figure A: Pulll the MAF sensor housing out of the air
box cleaner. Figure B: Unplug the vacuum line from the
factory air box cleaner. This vacuum line is next to the
opening where the MAF sensor use to go.
Figure A: On the right side of the battery, locate the
air box air duct and unbolt the 10mm nut . Figure B:
Now remove the entire air duct assembly
Now lift the entire air box cleaner out of the engine
bay.
Place the 2.75” straight hose and two 040 clamps
onto MAF sensor housing.
Location of other end of silicone TT intake hose in
the bumper cavity. Note the location of the horns
from figure 12.
Filter in correct location, free from any contact of
other parts. Once filter is in best position, tighten the
040 clamp onto the silicone hose.
Figure 15 Figure 16 Figure 17
Figure 18 Figure 19 Figure 20
Figure 24 Figure 25
Figure 23
Figure 21
Page 3 of Part# SP3072
ABAB
Air duct
040 clamp
Horn #1
Figure 26
A
B

Connect the supplied 6” long 6mm vacuum hose to the
1/4 aluminum coupler from figure 17. NOTE: Becareful with these two component in
the engine bay when install the intake tube.
Coming in contact with these can scratch the fin-
ish on the intake tube!
Align the intake bracket onto the vibramount and place a
fender washer and M6 nut onto the bracket. Use a 10mm
socket and rachet to tighten the nut to the vibramount.
Place the 1 1/2” X1/4” aluminum coupler into the
vacuum hose prevously removed from the air box
assemble in figure 15
Once you have made final adjustments for the best
fitment, use a 8mm nut driver and tighten the clamp
on the MAF sensor hose and also the clamp on the
TT silicon hose.
Now attach the 6mm vacuum hose to the welded 1/4”
on the Injen intake tube. Picture shown vacuum line
connected to intake tube.
Figure 15 Figure 16 Figure 17
Figure 18 Figure 19 Figure 20
Page 4 of Part# SP3072
1/4” nipple
Figure 21
Make sure everything is tighten. Position for best possible fit. Congratulations! You have just completed the installation of this intake system.
Periodically, check the alignment of the intake, normal wear and tear can cause nuts
and bolts to come loose. Failure to check the alignment and adjust the intake can
cause damage that will void the warranty.
1. Upon completion of the installation, reconnect the negative battery terminal before you start the engine.
2. Align the entire intake system for the best possible fit. Once the intake has been properly fitted continue
to tighten all nuts, bolts and clamps.
3. Periodically, recheck the alignment of the intake system and make sure there is proper clearance around
and along the length of the intake. Failure to follow proper mainentance procedures may cause
damage to the intake and will void the warranty.
4. Start the engine and listen carefully for any odd noises, rattles and/or air leaks prior to taking it for a test
drive. If any problems arise go back and check the vacuum lines, hoses and clamps that maybe causing
leaks or rattles and correct the problem.
5. Check the filter for excessive dirt build up. Clean or replace the filter with an original Injen filter (can be
bought on-line at “injenonline.com”). Congratulations! You have just completed the installation of the best
intake system sold on the market. Enjoy the added power and performance of your new intake system.
Figure 22