In this article, I will present the available methods for modifying the factory air guide in VW Polo 6R/6C. Although not all described solutions are currently available for purchase, they can serve as inspiration for creating your own modifications.
If you want to first learn about the theory of intake system operation, check out the first part of the article: air intake modification in VW Polo 6R/6C – guide: theory, diagnosis, basics.
To begin with, it’s worth explaining how the factory intake system works. The Polo 6R has a rather restrictive air channel located in the front bumper. The air channel part number is: 1T0805971 – it’s the same part that was in the Touran from 2003 (PQ35), the same air channel is used in Caddy III, newer Polo, Skoda Fabia II, Skoda Rapid, Ibiza IV, Audi A1, etc. It has characteristic mounting – on the left side, the screw hole is in the center, and on the right side, it’s above the center.
The inlet in it is quite narrow, but more problematic is the air guide – this is an element that is plugged into the air channel, usually together with the accordion pipe (the exception is 1.8 TSI, which has a factory air filter at the very front).
In the original solution, over 90% of the air is directed to the engine compartment, and only a small portion of it goes through the air guide (usually an accordion tube) to the air filter housing. Moreover, if we drive slowly or stand still, most of the intake air is drawn from the heated engine compartment.
The slower the speed, the more air will be taken from under the hood.
Airflow diagram based on channel 1T0805971:
In the above diagram, you can see how the flowing air during driving enters the engine compartment (lower arrows) and the air filter (upper band). Only a tiny portion is sucked upward, through the accordion pipe and further to the engine.
This is not optimal from an efficiency standpoint – especially at lower speeds when most of the air is taken from the heated engine compartment instead of from outside.
This solution has its advantages – the filter element wears out more slowly, and contaminants (dust, leaves, etc.) have limited access to the filter housing. Unfortunately, when attempting to increase engine power, such a significant restriction of airflow becomes problematic, especially on warmer days when we want to maintain stable torque.
The basis of most modifications is changing the air channel/air guide in the front bumper. Additionally, to be able to mount a larger air filter housing (even factory one), it’s worth considering relocating the battery from the engine compartment to the trunk.
Interestingly, the air directed to the engine compartment instead of the filter is not essential for the engine operation – this is evidenced by the fact that VAG’s sportier models (e.g., Audi S1) have an air guide leading exclusively directly to the filter. Unfortunately, VW often uses power-limiting solutions that become problematic especially when trying to increase engine performance.
Below I present the available modifications, grouped by engine capacity:
1.2 TSI EA111 Factory Intake Modification
Compatible engines: CBZC, CBZB
Factory Intake Modification for Polo 6R 1.2 TSI EA111 by vis
The modification involves blocking the inlet to the engine compartment, causing all air entering the air guide in the front bumper to flow directly to the air filter.
Below is an example of a plug made from 2-millimeter heat-bent plastic – photos by user vis from uk-polos perfectly demonstrate this:
source: https://uk-polos.net
Air Intake for Polo 6R 1.2 TSI EA111 by Jay-Jay
Air guide designed by Jay-Jay from Italy, which allowed him to increase power in the 1.2 TSI CBZB engine from factory 105 HP / 175 Nm to 133 HP / 233 Nm.
source: https://uk-polos.net/
1.4 MPI/1.6 MPI 16V EA111 Factory Intake Modification
Compatible engines: CGGB, CMAA, CNKA, CFNA itp.
In the case of naturally aspirated engines, usually, the intake doesn’t result in any power increase (even in trace amounts). It can help with engine cooling, but until you add a turbo or change the engine (as in my case), this modification doesn’t make much sense – unless someone wants to visually improve the engine bay appearance 😉
You might as well paint the air filter housing and the accordion pipe leading to the filter red – the effect will be more or less the same (nothing will improve, but it will give the impression of being faster).
Intake from NL-Carbon for naturally aspirated Polos with 1.4/1.6 16V EA111
3-piece set, according to the manufacturer increasing airflow by +130%.
The narrow section of the original air guide 6R0129618B is removed and replaced with a 65mm diameter silicone hose. It is plugged into the modified air channel using a carbon fiber adapter – replacing the factory channel 1T0805971.
In the case of naturally aspirated engines, this modification won’t make much difference anyway, so in my opinion, it’s moderately cost-effective apart from aesthetic values 😉
Price: 109 €
Musa2005’s Intake for Polo 6R 1.4/1.6 MPI
Modified air channel using the factory accordion pipe. Additionally, several internal walls were broken out inside the filter box, and the filter element itself was changed to a sports one from K&N.
source: drive2.com, drive2.com, drive2.com
cpsskipper’s and snake346’s intake for 1.4/1.6 MPI
Modified air channel, used in Skoda Rapid 1.6 MPI 110HP by cpsskipper from drive2. Better than the previous one because it has a much larger air-catching surface, and additional ribs should strengthen and stiffen the construction.
The air channel itself is changed, the project assumes the use of the factory accordion air guide.
Unfortunately, as is typical with naturally aspirated engines (MPI), increased air flow did not result in power increase – which cpsskipper and others described in the post comments on drive2.
source: drive2.com #1, drive2.com #2
1.2 TSI / 1.4 TSI EA111 Factory Intake Modification
Compatible engines: CBZC, CBZB, CAVE, CTHE.
NL-Carbon’s intake for Polo 6R 1.2 TSI and 1.4 TSI EA111
Air guide with accordion pipe for VW Polo 6R with 1.2TSI/1.4 TSI engines from the VW EA111 family.
source: https://www.facebook.com/share/1AfXo6dJvz/ / https://www.facebook.com/share/p/15HFroxAUt/
kW-Extreme’s intake for Polo 6R 1.4 TSI EA111
Similar, if not the same solution as in the case of NL-Carbon. Modified air channel that uses the factory accordion air guide.
Article number: 2028
Price: 129 EUR + 29 EUR shipping
Manufacturer’s website: kw-performance-parts.de
1.0 TSI / 1.2 TSI / 1.4 TSI EA211 Factory Intake Modification
Compatible engines: CJZC, CJZD etc.
Dave Kamperman’s air intake for Polo 6C 1.2 TSI EA211
The same idea as above, but executed by different people and for the newer generation of 1.2 TSI EA211 engine. The project authors are: Dave Kamperman and Tim Eastwood from the Polo 6r / 6c Owners Club UK..
Price: 70 USD (for the air guide only, without silicone and clamps)
NL-Carbon’s intake for Polo 6R/6C 1.4 TSI and 6C 1.0 TSI EA211
Air guide designed for 1.4 TSI EA211 engines (Polo 6R/6C BlueGT) and 1.0 TSI EA211 (Polo 6C). Increases the cross-section of collected air by 22%.
Price: 139 €
mcaserg’s air channel for 1.4 TSI EA211
Modified air channel for Polo BlueGT with 1.4 TSI EA211.
source: drive2.com
1.8 TSI EA888 Factory Intake Modification
Compatible engines: DAJA, DAJB
Air filter: 6C0129607P
Factory intake mod in 1.8 TSI EA888 – closing the engine inlet
Modification similar to the one used with the air channel in the 1.2 TSI EA111 engine. Closing the inlet to the engine compartment increases the amount of air flowing directly into the accordion air guide.
source: Polo 6R/6C GTI / Marvin Brodivić
NL-Carbon’s intake for Polo 6C GTI 1.8 TSI EA888
Air guide made from genuine carbon fiber. In 2016, it could be purchased on ebay.de for about 150 EUR.
CRN Motorsport’s intake for Polo 6C GTI 1.8 TSI EA888
Modified air guide for the air filter from Polo 6C GTI 1.8 TSI. Looks roughly like a copy of the earlier intake from NL-Carbon, although here the room for maneuver is so limited that it’s hard to come up with something different.
Matthew William’s intake for Polo 6C GTI 1.8 TSI EA888
Similar to the above, an air channel increasing flow directly to the air filter.
source: Polo 6R/6C GTI Owners Club
2.0 TSI EA113 / 2.0 TDI EA189 Factory Intake Modification
Compatible engines: CDLJ, CDLH, CFHD.
Air filter: 6R0129607J / 8X0129567
Air guide: 1T0805971 + 6R0129618E.
CaziuzDesign’s air guide for Polo 6R 2.0 TSI EA113/2.0 TDI EA189
This modification uses the original air channel 1T0805971, however, the air channel at the accordion pipe has been replaced with one that directs all captured air to the accordion tube.
source: makerworld.com
NL-Carbon’s intake for Polo 6R 2.0 TSI EA113/TDI EA189
Intake for the factory air filter box from 2.0 TDI EA189 / 2.0 TSI EA113. Inlet surface increased by 60%, according to NL-Carbon’s claims, the intake change alone in Polo 6R WRC Street increases power by +9KW/14NM.
source: facebook.com/share/p/1DHZ3ZZUt7/ / facebook.com/share/p/15s1TFgxrA/
CRN Motorsport’s air intake for Polo 6R 2.0 TSI/TDI
CRN Motorsport’s project from Sweden, which allowed achieving 350 HP / 500 Nm on the factory Polo air filter. The intake is designed for the factory air filter box from 2.0 TDI EA189 / 2.0 TSI EA113 (factory installed in Ibiza 2.0 TDI, Audi A1 2.0 TDI, Audi A1 Quattro 2.0 TSI and Polo 6R 2.0 TSI, but it can be equally well fitted to any other Polo after battery relocation.
3D Render in carbon:
Here you can also clearly see the inspiration from NL-Carbon’s kit, however, it’s noticeable that the channel height is slightly greater (it’s mounted just above the radiator, allowing it to catch more air).
Printed kit:
CNK’s air intake for Polo 6R 2.0 TSI/TDI
Intake based on photos from NL-Carbon and CRN Motorsport. The final version was created after many trials, finally printed from carbon fiber reinforced nylon, so it should easily withstand higher temperatures. Instead of the standard accordion pipe, I use a 3.5″ industrial PUR hose, which is also adapted to work at high temperatures.
More information about this intake will be in a separate post – once the testing is complete 😉
