R50/R53 :: Hatch Talk (2002-2006) Cooper (R50) and Cooper S (R53) hatchback discussion.

R50/53 Tips for installing DDMworks intake

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Old Nov 2, 2020 | 09:40 AM
  #1  
dayman's Avatar
dayman
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Tips for installing DDMworks intake

I attempted to install the intake about 30 minutes ago, but I gave up and stuck the original airbox back in because of fitment issues with the DDM intake housing. The two front phillips screws wouldn't align with the bottom portion of the airbox, I tried moving the metal around and pulling but I couldn't get the screw in right, it would end up lopsided.

The metal sides also wouldn't line up with the bottom airbox and seal leaving some small gaps. Anyone else have trouble installing this? Maybe I should take out the lower airbox and then assemble the DDMworks into it first, then attach it to the firewall screw holes.



 
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Old Nov 2, 2020 | 09:13 PM
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That's a huge photo! Try again, I know it took me a little massaging to get it to fit correctly, but it fits, don't give up.
 
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Old Nov 3, 2020 | 07:02 AM
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Originally Posted by jk6672
That's a huge photo! Try again, I know it took me a little massaging to get it to fit correctly, but it fits, don't give up.
Yeah I'll give it another go. Maybe take a hair dryer and some vaseline with me to heat the intake hose as well, because it refused to go on.

If there are little gaps where the metal aligns with the bottom plastic airbox, is that a problem for heat getting into the air intake?
 
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Old Nov 3, 2020 | 07:10 AM
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you could go get a roll of foam tape from hardware store... single adhesive backed applied to the lower box might do it... or. black tape across the seam.
 
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Old Nov 4, 2020 | 11:00 AM
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Finally got the intake onto the lower airbox, I just took it out and brought it in. Next step is getting that damn hose onto the airbox snout.
 
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Old Nov 4, 2020 | 01:10 PM
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lube inside of hose with oil or wd40, it shouldn't take much, a couple drops or a dip of a finger goes a long way.
 
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Old Nov 4, 2020 | 02:13 PM
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Originally Posted by Jason Cornelius
lube inside of hose with oil or wd40, it shouldn't take much, a couple drops or a dip of a finger goes a long way.
I got some vaseline and lubed it up on the snout and inside the hose, and with the help of a flathead screwdriver I got it onto the intake. So success!

Took it for a test drive and the supercharger whine is very pronounced, increasing smiles per gallon.
 
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