 | Home > Puma (Tdci) > Removal of air intake pipe 2.4 puma |
 
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 19608  
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Removal of airbox is easiest but you will need rivets to replace the drilled out ones Diesel$ Live$ Matter. ⛽️🛢️👨🔧🧰⚙️ RED, WHITE & BOOST! 🇬🇧
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10th Oct 2016 11:18pm |
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| carrotbay Member Since: 18 Aug 2013 Location: Northants, UK Posts: 695 
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Hi Steve
The problem I have is getting the larger bit of the plastic moulding past the brake servo. Is it easy enough to remove the inner wing enough to get it past? 2008 Defender 110 XS SW - M57N2 / 6HP28X |
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10th Oct 2016 11:27pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 19608
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Can't quite get my bearings exactly there but I know what you mean.
With various jiggery pokery you should get it out, others I think have been known to just chop it and bin instead. I think it needs to be pushed down somewhat with the end nearer the front tilted up if that makes sense. I know the damn thing was a sod to seal earlier this year much less remove, I've kept mine in situ but sealed with my Safari. As tested there is little difference so long as rain separator is removed. Diesel$ Live$ Matter. ⛽️🛢️👨🔧🧰⚙️ RED, WHITE & BOOST! 🇬🇧 |
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11th Oct 2016 12:02am |
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| tuesdayfox Member Since: 23 Jun 2013 Location: Sydney,OZ Posts: 129 
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well
I have replace the factory air intake to the airbox and also fitted silicon hose. the easiest way is, if you wish, to cut it. they are alll friction fitted there so just make two cuts and yank them out violently.... (in a summer day...) by the way I have also taken out the airbox, but you have to disconnect the air con pipe first. once the pipi is disconnected, you can easily lift the airbox out after you free it from its three rubber mounts. you dont need to remove the rivet and reinstall the rivet using this method. but you will need to regas your air con. yes I know it is illegal to vent the gas to the atmosphere, but hey, you can get the aircon gas cans almost every where. just my 2 cents. cheers Maritn |
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11th Oct 2016 2:33am |
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| Roy5695 Member Since: 15 Feb 2014 Location: Cornwall Posts: 1123 
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The easiest way is to take the airbox out, this can be done without disconnecting the aircon pipe or drilling any rivets off, you just need some strength and alot of patience.
The airbox is secured with 4 rubber bushes, 2 on the bottom and 2 inside the wing, spray some form of lube on these the best you can and pull! be careful as there's not much room there and it can let go quite quickly. Then the patience part comes in, now you have to work out how it comes out, I have done it many many times during the trial fitting of my one piece silicone intake pipe. I think I broke 2 or maybe 3 airbox bottoms in the last 2 years of ownership due to getting a little frustrated whilst trying to get it out and getting it in isn't much better. You can make it a little easier if you unbolt the bottom mount, these bolts can be accessed in the passenger wheel arch towards the front, on this though there is a bracket that holds the intercooler pipe so make sure this goes back on. Once the airbox is out you need to remove the inner wing to outer wing bracket, you should then be able to manoeuvre the plastic pipe out. While the airbox is out it would be worth while doing the airbox mod, there is a post on the forum detailing what this entails. 2011 Defender DCPU 2.2 - https://www.defender2.net/forum/topic30623.html Instagram - @r22oyp Roy |
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11th Oct 2016 7:47am |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 19608
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^^^^ Why do that and risk breaking stuff when the rivets cost peanuts in comparison? Diesel$ Live$ Matter. ⛽️🛢️👨🔧🧰⚙️ RED, WHITE & BOOST! 🇬🇧
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11th Oct 2016 5:13pm |
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| Roy5695 Member Since: 15 Feb 2014 Location: Cornwall Posts: 1123
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ideas from many can sometimes give the solution to one.
There are many ways to skin a cat. You can decide whichever way you choose. I once got my airbox out and in, in about 10minutes. Another time it took me over an hour or so and broke the airbox. Both the same way. Must depend on how aligned the planets are.  2011 Defender DCPU 2.2 - https://www.defender2.net/forum/topic30623.html
Instagram - @r22oyp Roy |
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11th Oct 2016 5:45pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 19608
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They aren't the best made things, mines broken just on the top edge.
I didn't do it myself so someibe knows something about it! 
Luckily it's only a very edge and I no way affects the airbox, filter etc. How much are they? Diesel$ Live$ Matter. ⛽️🛢️👨🔧🧰⚙️ RED, WHITE & BOOST! 🇬🇧 |
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11th Oct 2016 5:47pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 16892 
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If you don't have aircon and don't have ABS then getting the pipe out is a doddle.
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11th Oct 2016 7:08pm |
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| Roy5695 Member Since: 15 Feb 2014 Location: Cornwall Posts: 1123
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I got both my replacement box's from a well known auction site for around 20 each. The dealers will only sell you the whole box for a ridiculous price, over 200 if I remember correctly. I also have two spare MAF meters now.
2011 Defender DCPU 2.2 - https://www.defender2.net/forum/topic30623.html
Instagram - @r22oyp Roy |
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11th Oct 2016 7:27pm |
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| carrotbay Member Since: 18 Aug 2013 Location: Northants, UK Posts: 695
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Thanks for the replies.
I've had the air box out and back in again over the weekend to fit an adaptor for the new intake pipe. The dog learnt some new language in the process .. pig of a job. Managed to break a clip off the air box but no other damage apart from knuckles. I've cut a couple of sections off the intake pipe but still not convinced it's going to come out without taking apart the wing or inner wing. I have air con and abs so it's pretty crowded. I'll have another look tomorrow evening. 2008 Defender 110 XS SW - M57N2 / 6HP28X |
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11th Oct 2016 9:40pm |
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| Roy5695 Member Since: 15 Feb 2014 Location: Cornwall Posts: 1123
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It certainly comes out if you take the inner wing to outer wing bracket off. Mine came out in one piece and was replaced with a proper one piece.
[URL=]  Click image to enlarge[/URL] Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated  2011 Defender DCPU 2.2 - https://www.defender2.net/forum/topic30623.html
Instagram - @r22oyp Roy |
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11th Oct 2016 9:49pm |
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| tuesdayfox Member Since: 23 Jun 2013 Location: Sydney,OZ Posts: 129
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there are screws on the atmosphere end of the intake. take those screws out and yank the ducts out. you can see where the sections overlap each other. |
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12th Oct 2016 7:22am |
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| chinnus Member Since: 24 Aug 2012 Location: UK Posts: 119 
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Roy where did you buy the silicon pipe from ?? Looks great Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated |
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12th Oct 2016 11:44am |
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