Why this procedure?
I had read in several forums a process that people had built for modifying their stock air box to allow for increased free flow of air. In looking at the procedures, and comparing them to my stock ’06 air box, I found enough differences to make them notable, then decided to go ahead and do a step-by-step process with photos so that others with ‘06> PT Cruisers could use my process to their benefit.
Tools and supplies needed:
The following items I found useful during this modification –
• Paper towels
• Two flat tipped (standard) screw drivers; one large, one small
• Work light / drop light
• Pen, marker or pencil for marking
• Hack saw / core saw / fine bladed saw for plastics
The following steps were used on MY PT Cruiser and worked for me. I can not guarantee your results, nor am I in any way liable for any outcome (unless of course it works great, you gain lots of torque and hp, then you can send me money via PayPal). If you mess up your car, don’t come crying to me. The steps I’ve documented worked fine, were completed slowly, in a thoughtful manner to reduce the chances for damage. However, I still had issues, as are documented below, and you should be aware of those. If you deviate from this procedure and find a better method, please let me know by PM’ing me on these forums. If you totally screw up, forget you ever heard of me!!! This entire process took about 1 hour, but I tried several additional steps that weren’t necessary, so your efforts should take less than an hour assuming you have all the tools at hand.
1. Loosen the clamp screw on the TTAB hose (also known at the “throttle body air inlet hose” – see circled area in figure 1). Unclip the two retaining clips that hold the air box cover in place – one on the front right, the other on the left side.
2. Gently lift the front of the air box and pull it towards the front of the car. There are three tabs at the back, towards the firewall, that you have to clear to have the cover free. The cover should also slip off the TTAB hose. See figure 1:
3. Now flip the air box cover over, and you will see the baffle that is connected to the pipe leading to the TTAB hose (see figure 2). This is simple to remove, HOWEVER, follow these instructions carefully and do not try prying this out! Note the tabs in Figure 2 – do not try to pry these out, you will end up breaking something! Simply use a small, flat tipped screwdriver inserted at the top between the baffle and the cover wall. You will see a retaining clip there once you’ve got it open just a bit (see Figure 3). Once you see that clip, very simply use a couple of fingers to slide the baffle out of the cover.
4. Now you can simply dispose of the baffle, or do with as you please. You’ll note it’s a two part system, I have them labeled here A and B. See Figure 4: