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Discussion Starter · #1 ·
Just got in from the garage after what I thought was going to be a simple job ... -> replacing the air filter.

I unclipped the box.
Removed the old air filter.
Inserted the new filter in the base.

I tried to slide the lid to hook in the 3 plastic clips - but at this point I noticed the plastic air filter box seemed warped. I think perhaps a previous mechanic may have misaligned the side tabs hence putting pressure on the box - which combined with the heat have deformed the box. Maybe around 5 to 8mm.

I guess the only solution here is to buy a new air filter box?
 

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2021 Volvo S60 T5 FWD
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If it's only 5~8mm, you can't just shut it and clip it closed the correct way?
 

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Discussion Starter · #3 ·
Re: (StarmanDXE)

These are some pics WITHOUT the filter in place .. just trying to get it right without the extra hassle of the filter in there. As you can see there is quite a large gap and I don't think the seal would be correct.

The clips are attached here .. I have pushed the tabs into the sockets but due to the warping of the housing, you can see the gap ...


Another photo with the clips locked in place, but unfortunately the large gap is still there ...


You can even see the warping of the box with it detached ...


Modified by SML at 6:39 AM 3-11-2009

Modified by SML at 6:40 AM 3-11-2009
 

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Discussion Starter · #4 ·
Re: (StarmanDXE)

Quote, originally posted by StarmanDXE »
If it's only 5~8mm, you can't just shut it and clip it closed the correct way?

In theory, yes ... but I think there will be a risk of running some sand & dirt through the engine!
 

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I can't tell what the problem is. Seems kind of hard to show with pictures(?) To me, it looks like the hinge part just isn't put back together correctly...
 

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Discussion Starter · #6 ·
Re: (StarmanDXE)

Quote, originally posted by StarmanDXE »
I can't tell what the problem is. Seems kind of hard to show with pictures(?) To me, it looks like the hinge part just isn't put back together correctly...

I added a few comments above the photos.

Have you changed the air filter yet on your S60? If you have, then I think the photos should be straightforward to highlight the problem. ?
 

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Re: (SML)

I didn't change it, but I have removed it.

Like I said, looks like the hinge isn't in correctly... Is there more to it?
 

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i have the exact same thing!

i bought this.....works great to push the airbox back out.

http://www.homedepot.com/webap...01411

i have to do it everytime but it works like a charm.

and another option which Tech from Volvoforums says to do is file down the plastic tabs the hook under it, which will make it slide in easy. but my way worked fine and i dont like permanatly changing things on my cars.
 

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Re: (SML)

Quote, originally posted by SML »
It is aligned and I can push it into the slots but then it flexes back out.

Perhaps I can heat the plastic then try to bend back into shape?

I thought I had that same problem too on my car, however, I inserted the angled tab into the slot FIRST and then the other two just followed in.

I disconnected my mass airflow sensor, as well. Did you do this?
 

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Re: (Paysts)

I had the same problem with my airbox when i bought my car, someone carelessly problably did this when they were replacing the air filter. Only mine was 5X worse. You could actually see part of the edge of the actual filter. What I did was take a small block of wood and wedged it inbetween the fuse box and airbox so that the pressure was holding it closed fully so there was no gap. And I left the block of wood in there between the fuse box and airbox for about a week, even drove around with it in there, and after about a week the heat from inside the engine bay combined with the pressure created by the wood pushing up against it caused it to go back to normal.
 

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Discussion Starter · #13 ·
Re: (DGBibo)

Quote, originally posted by DGBibo »

i bought this.....works great to push the airbox back out.
i have to do it everytime but it works like a charm.

How do you use it? Do you somehow insert the clamp inside the top airbox housing, then apply outward pressure with the clamp, then put into an oven to heat-up?
 

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Discussion Starter · #14 ·
Re: (Paysts)

Quote, originally posted by Paysts »

I thought I had that same problem too on my car, however, I inserted the angled tab into the slot FIRST and then the other two just followed in.
I disconnected my mass airflow sensor, as well. Did you do this?

Thanks .. wish I read the first tip before I had started! It took me an hour to work-out that I need to insert the angled tab first!

I did not disconnect the MAS - but when I go back out to try again, I will disconnect the MAS.
 

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Discussion Starter · #15 ·
Re: (bpray9223)

Quote, originally posted by bpray9223 »
What I did was take a small block of wood and wedged it inbetween the fuse box and airbox so that the pressure was holding it closed fully so there was no gap

Sounds almost like a great plan, but if you wedge the piece of wood between the fuse box & air filter housing this will push the air filter housing inwards.

I need to push the bottom half of the housing INWARDS - your plan will do this - great - thanks

BUT I need to push the top half of the housing OUTWARDS.

Perhaps I could cut a piece of wood to insert inside the top housing - almost like a brace to push it outwards!
 

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I have the exact same thing going on with my airbox. It looks like someone took a screwdriver and pried the back half of the box open. I just use some extra K&N grease to seal up the airbox and it works fine.
 

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Discussion Starter · #17 ·
Here is my solution:
1. Cut a piece of wood about 7" long and push it into the top housing to brace it open.
2. Install air filter into base.
3. Slide top housing onto base - such as easy fit with the bracing! 5 seconds!
4. Wedge a piece of wood between the fuses and the base.
5. A perfect fit!

Hopefully with some heat, the shape will remould back to normal!
 
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