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Reattaching the rubber intake boot.
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Reattaching the plug on the MAF sensor
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The hose for the air pump clips on to the billet fitting on the P-Flo shield.
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Neuspeed's P-Flo comes with a re-useable cotton filter element.
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Here is the intercooler inlet pipe in the passenger-side wheel well. Note how it's flat and constricted.
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There are two clamps on either end of the pipe that must be removed.
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On the intercooler end, it's easier to remove the short hose section at the intercooler.
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The pipe attaches to the frame rail in one place.
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With the hoses and mounting nut removed, the pipe can be maneuvered free of the car.
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The rubber grommet from the old pipe is re-used on the larger Neuspeed part.
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The new pipe is maneuvered into place.
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Fastening the pipe to the frame rail.
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Attaching rear hose.
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Attaching the front hose. We're now done with the mechanical part of the front half of the car.
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To remove the exhaust, you must cut the center from the rear. Here on this exhaust (shown on an early 2.0l Beetle,) you'll see three dimples. Cut at the middle one.
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The rear exhaust is mounted to the car with rubber hangers. Replace if cracked.
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The rear exhaust hanger.
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If you have a lowered suspension, the left rear shock mounting bolt must be removed in order to drop the suspension. You'll need a jack to prop it up again, as well as a person to put some weight on it. This stresses the importance of using jack stands and lifts.
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Here the rear exhaust section is being pulled free.
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This clamp attaches the center section to the catalytic converter. The goop on the pipe is remnant sealer paste. After all, this is a test/development car.
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The center exhaust is supported by the boomerang-shaped bracket.
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Remove the nuts to remove the center exhaust support.
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Upon removing the support, the entire rear exhaust section can be removed.
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The downpipe attaches to the turbo housing with four nuts. We had the exhaust downpipe prepped ahead of time. I'd personally leave that to a muffler shop.
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Look at the clean welds where the new downpipe is mated to the catalytic converter.
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Here the Neuspeed center section of the exhaust is being fitted to the support bracket.
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This German Wurth exhaust paste is applied to the pipe joint to ensure leak-free fitment.
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Mating the new center section to the catalytic converter pipe.
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Re-installing the exhaust is a reverse of the disassembly.
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Unlike the factory exhaust which is welded together, the rear and center sections of the Neuspeed exhaust is joined with a flange.
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The next step is the "software" upgrade, which requires removing the Motronic computer and sending it overnight to Neuspeed. The box is under the front cowl. Start by removing the wiper blades, beginning with this decorative cap.
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One nut attaches the wiper arm to the spindle.
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Pull the wiper arms free.
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This rubber strip holds down the front edge of the plastic cowl.
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The plastic cowl attaches via a groove in the back. Carefully lift it free.
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Each of the two plugs has a retaining mechanism. Slide the lock towards the outside of the car. The plug can then be released.
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The box can now be pulled free and shipped off to Neuspeed for upgrading.
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This is an open engine management computer. This particular one has the chip on a removable board. This is so Aaron can plug in a laptop emulator for on-the-fly development. Most are soldered directly to the board.
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Viola, we're done and ready to spin the rollers on the dyno. Read the April, 2003 issue of ec for a report on how these modifications measured up.
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