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My left front air duct has a section that is disintegrating. As noted on other posts here, it’s a result of the proximity to the oil fill with some oil having dripped onto it and time. (First picture). I decided to purchase the air duct from my local dealer and attempt to replace it myself.
This DIY requires a few socket torx bits and a bit of patience. There are three pieces that need to be removed to gain access to the air duct. Two are plastic, and one is metal.
1. Start by removing the six torx screws that hold the top plastic piece to the front grill assembly.
2. CAREFULLY pull back the top of the grill assembly away (about three or four inches and place a non-marring item to keep it there and cover the grill assembly to protect it.
3. Remove the screws from the top and middle plastic assemblies and set aside.
4 Now remove all of the screws from the metal plate and remove.
5. Disconnect the electrical connector near the tip of the air duct. You will need this room to remove the air duct.
6. I used a small flat screwdriver to pry the tabs to release the air duct. Start on the tip end and work your way back to the connector to the middle air duct.
7. Once all the tabs are released, work the duct out from the tip first. It’s a very tight fit, but the accordion section flexibility helps to get it out.
8. Insert the new duct large end first and line up the front end carefully and press into place.
9. Re-connect electrical connector.
10. Re-assemble plates and grill assembly in reverse order.
**Note - the last plastic piece sets the gap between the grill assembly and the bonnet. (Ask me how i know)
Start by fastening just a few screws and checking the gap, then adjust if necessary and set the rest of the screws.