Removing and installing air filter housing, Polo: VW 1.6 TDI (CAYA, CAYB, CAYC)

🧭 Before you start

Fits: VW Polo 6R (2009–2014)

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• As it is difficult to gain access to clip on intake hose beneath, it is better to remove intake connecting pipe from turbocharger.
• Completely undo bolt (4) (make sure bolt is captive).

🔧 Engine codes this applies to

📐 66 workshop diagrams for CAYA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove engine cover .
2. Release catches (arrows), remove air duct (1).
3. Unclip bracket (arrows) together with vacuum hoses from air filter housing.
4. Disconnect electrical connector (3).
5. Remove intake hose, loosening hose clip (2) to do so.

6. Remove air hose; loosening hose clip (1) to do so if there is one.
7. Unscrew bolt (4) and remove air filter housing. [Note: As it is difficult to gain access to clip on intake hose beneath, it is better to remove intake connecting pipe from turbocharger.]
8. Remove crankcase breather hose (3).
9. Pull vacuum hose (2) off intake hose (1) and move to side. Unclip bracket.
10. Completely undo bolt (4) (make sure bolt is captive).
11. Swivel intake connecting pipe to the right and remove together with intake hose (1).
12. When mounting intake connecting pipe on turbocharger, it must be ensured that intake connecting pipe is correctly seated on the bolt of the turbocharger. (arrow). [Note: A clean air filter housing is essential.In order to avoid functional problems, you should cover the critical air-conducting components such as air mass meter, air pipes etc. with a clean cloth when blowing out the air filter housing with compressed air. Hose connections and air intake pipes and hoses must be free of oil and grease before installation.Use a silicone-free lubricant when installing air hoses.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic Parts Catalogue.]
13. Check air intake hose for salt residue, dirt and leaves and, if necessary, clean.
14. Check air duct leading from lock carrier to air filter housing for dirt and leaves. Clean if necessary.
15. Guide water drainage pipe (arrow) between gearbox and body.
16. Check under the wing to see whether the water drainage pipe has been installed correctly.

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