JCW 210 Replacement Airbox Flap

A$25.00

This product is designed as a replacement for the OEM Airbox Flap found in JCW 210’s.

Commonly the airbox flap was removed to allowed uninhibited flow from the cowl area, with many people beginning to return their cars to a stock JCW configuration, unfortunately the OEM Airbox flaps are long gone, so I designed a replacement to fill the requirement.

This is a Resin 3D printed component designed by myself with measurements taken from an original flap, there is a slight ramp on the area which the lever arm attaches to simply to allow easier 3D printing and strengthen that area.

Due to the nature of 3D resin printing scratching may occur during transport, i wouldn’t expect it to be significant, but reference the scratching from the photos to determine what is a normal level.

This product is designed as a replacement for the OEM Airbox Flap found in JCW 210’s.

Commonly the airbox flap was removed to allowed uninhibited flow from the cowl area, with many people beginning to return their cars to a stock JCW configuration, unfortunately the OEM Airbox flaps are long gone, so I designed a replacement to fill the requirement.

This is a Resin 3D printed component designed by myself with measurements taken from an original flap, there is a slight ramp on the area which the lever arm attaches to simply to allow easier 3D printing and strengthen that area.

Due to the nature of 3D resin printing scratching may occur during transport, i wouldn’t expect it to be significant, but reference the scratching from the photos to determine what is a normal level.

Installation Instructions:

  1. Open Bonnet and Boot

  2. Remove Negative Battery Terminal from the Battery in the Boot

  3. Go back to the front of the car and remove the ECU cover to the right of the airbox

  4. Gently Slide the retaining clips back, removing the plugs from the ECU

  5. Undo 1x 10mm bolt on the RHS of the airbox- Also retains the closest ECU cabling to yourself at the front of the car.

  6. Remove the plastic cold air duct from the airbox, using a pulling motion towards the front of the car and a slight anti-clockwise twist motion.

  7. remove the hoseclamp holding the intake tube to the airbox.

  8. Lift and pull airbox out of car towards you, ensuring main power-feed cabling on the Left hand side of the airbox is juggled from the slot and vacuum tube and Actuator cabling is disconnected from the left hand side of the airbox.

  9. Once airbox is out of the car use a phillips head screw-driver to remove the 4 retaining screws from the rear of the airbox

  10. Insert the upper actuating arm into the knob section of the airbox flap, and gently lower the side pieces into the available slots.

  11. Route the Vacuum tube around the lower section of the airbox intake from cowl

  12. Reinsert the 4x phillips head screws holding the upper section on

  13. ensure airbox flap actuates by hand, a gentle push with your finger on the bottom side should allow it to open to a flat configuration and close right back up.

  14. Reverse procedure from step 8 to reinsert airbox and all cabling and tubes.