Corolla2.0D Saloon Air Intake Noise Problem Solved

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shaan (shaan) 2006-08-15 03:38:00 +0500 #1

While thinking over the issue it occured to me that if the air filter element is not properly seated in its place in daewoo racer the engine noise increases Thus i opened my car hood and observed the air intake unit closely.On removing the air filter i found 2 small holes in the lower body of the air filter unit body.I sealed these with clear silicone.then i observed the intake pipe between engine and air filter unit body the pipe was attached to engine with a screw lock and to the unit body with screw lock.i tightened these any way to make sure none was lose.The pipe entering in the upper unit body was properly tightened with no possible movement as it was a part of the unit.the pipe running from unit to sound box and then towards the R headlight located in the lower part of the unit body was movable.I removed the pipe portion(to remove remove the battery by removing holding bar and battery terminals,loosen the nut attaching the pipe to fender body near sound box--becareful not to damage the ac pipe,remove lock with help of screw driver located on the front chasis body.Then remove it slowly while pressing the lock of pipe located in the A.F filter box)
The entry gap in the A.F unit box was sealed by a foam around the pipe.The sound box connection to pipe was sealed with foam around sound box pipe.there were four holes in the pipe portion between sound box and A.F unit. I closed the four holes in the pipe by silicone and let it dry first---besure to clean the pipe from inside for excessive silicone entering the pipe thru holes during the procedure by a cloth forced in the pipe. Then I applied silicone around the pipe just adjacent to foam and in the portion of hole for pipe in A.F unit. i applied silicone on the soundbox opening area adjacent to foam and on the opening in pipe for sound box.then i quickly intalled the pipe and tightened the nut.wiped of excessive silicone around opening if any--be careful not to clean the silicone of the area required to be sealed.Applied silicone with hand to area inside the F.A unit where pipe was installed so that to seal it permanently.Be sure to apply silicone generously on the lower side of pipe as after installation one can not reach area with hands.Let silicone dry for 2-3 hours.Standing vehicle noise is reduced but while driving only engine sound heard no air intake sound heard

NOTE:-for better silicone grip kindly rub the areas where silicone will attach with rubbing paper(Rage Mal) so that they become rough---remember to clean the post particles generated with rubbing

The Same Implies For Xli,Altis.All use same Intake unit thus there sound at high speeds is also diminished

Japanese use proper clips in these regions thus no sound in there car whereas pakistani manufacturers use foam

Providing pictures is hard at this stage as it all sticked together but i have explained it so elaboratly that once you go and open the battery all the intake part will be visible and you can easily understand the steps i have mentioned above

testdriver (testdriver) 2006-08-15 05:11:00 +0500 #2

:S......Post atleast the engine bay pics to elaborate further.....

robin (robin) 2006-08-15 05:53:00 +0500 #3

good one (y)
but a repost, though pics could ve made this post a li'l bit more interesting. anyways nice job done.

shaan (shaan) 2006-08-15 07:19:00 +0500 #4

@testdriver
Thanks!!
But not possible as you cant practically see the modification as hidden in joint places

@robin
Thanks!!!!

muhd86 (muhd86) 2010-03-23 14:23:18 +0500 #5

bhai post some pics of what u have done so we all can do it .

Porsche_Maker (Porsche_Maker) 2010-06-23 18:09:49 +0500 #6

@shaan

Some demostartion by sketches can really help

KKNIAZI (KKNIAZI) 2010-06-24 10:21:24 +0500 #7

There is no need to carry out mods, just buy OEM air filter which used to cost Rs. 1200 in KHI.

The after market filters and I have tried all, will rattle if the RPM goes above 3K (stationary or moving) and the cushion around the walls in after markets one's is not enough to dampen the effect. What people have been doing is using after market and applying silicone on the walls to glue it with the bed walls and then arrest the rattling.

Cheers,
Kaleem

VCheng (VCheng) 2010-06-24 11:28:23 +0500 #8

" just buy OEM air filter" is good advice.

Most (not all) of the aftermarket filters are inferior to the OEM stock air filter for its true purpose: to filter the incoming air.

KKNIAZI (KKNIAZI) 2010-06-25 06:45:02 +0500 #9

Well! You got me here.......

Actually, if you go for after market, even the best Malaysian/Japanese ones cost no more then Rs. 400, thats saving of whopping Rs. 800, if you buy OEM from market and another 300 or so if you buy it from dealer. You really have to dig deep in your pocket, if you change air filter every 2nd/3rd oil change i.e. max 10000 KM.

In PK, the gaurd/QA-IM filters are really good if you can find the REAL ones but in case of 2.0D, local or foreign all failed because of their hard rubber seal.

There is another very info. thread about air/oil filters in PK, well researched and argued esp. by AHSANz.

I have been using Malaysian oil filters and change every 3K KM and I am telling you by experience (read disection) they are close if not at par with OEM and since I changed it every 3000 KM, so deterioration is minimal.