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Mangoletsi MOD4 Performance Upgrade - Cone Shaped Air Filter Going Rusty

27K views 85 replies 25 participants last post by  Aeroresh  
#1 ·
To all alfaowner members who over the past 12 months have had our MOD4 Upgrade fitted to their 2.2JTS or 3.2V6 Alfa 159, Alfa Brera or Alfa Spider.

After having reports from some customers that the cone shaped filter that we fitted as part of the upgrade was showing signs of rust, we decided to change our supplier - we now use (and have done for several months) a K&N Cone Filter with Samco Sport tubing (see photo below) which we are assured from our supplier should never rust and survive the lifetime of the car.

If any customer who has had our MOD4 Upgrade has a cone filter on their car showing signs of rust please contact our Service Department to arrange to come in and we will replace it for you free of charge while you wait with a new K&N version. Alternatively for those customers who maybe live a long distance from Mangoletsi who have a rusty air filter please contact our Parts Department who will gladly post a replacement to you free of charge for you to fit yourselves. The sporty noise and performance remain the same with the old filter or the new K&N filter so only replace it if you see signs of rust.

Mangoletsi apologise for this inconvenience and are happy to offer this solution to anybody who is affected.

Performance Upgrades MOD1,2,3,5,6,7,8,9 and 10 are unaffected.

Regards
Mangoletsi
 

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#7 · (Edited)
To all


If any customer

Mangoletsi apologise for this inconvenience and are happy to offer this solution to anybody who is affected.


Regards
Mangoletsi
The new parts look great but all, any, and anybody:rolleyes:
 
#8 ·
I've just had the right hand wheel arch protector off to investigate this.There were eight crosshead screws,six of which were fixed into nylon inserts and two which were fixed using the dreaded Alfasud metal to metal clips.No need to tell you that the rust has started,so liberal dollops of copper grease on reassembly.The gauze containing the cotton element on the cone filter is rusting nicely.
 

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#9 ·
That's not that bad compared with mine and one I've seen beloning to my pal Martin was totally clogged with rust.

Fingers crossed you get a replacement.
 
#11 ·
Hi

Do you sell the K&N Cone Filter with Samco Sport tubing separately?
They cost about ÂŁ45 Graham (priced using the parts supplied to Leigh).

Hopefully this thread explains why I didn't send you my 159Ti filter bits as promised and why I went quiet.

Contrary to certain people's beliefs I didn't blurt out that the kits were poor quality to all & sundry:(
 
#15 ·
I have had Mod4 done on my 2.2 and I can see signs of this issue. However, as I live in Kent I plan to get Mangos to post it to me. Can someone explain how to fit this? Do I need to jack up the car and remove the front drivers side wheel and wheel arch protector (looks like it seeing Baloney's pics above) or can this be accessed from the bottom by removing the bottom tray? Also, looking at the pics it seems that the other end of the tubing attached to the filter cannot be easily accessed. Can someone give me a step by step instruction as I attempt to do this for the first time?
Cheers.
 
#41 ·
Wheel off, wheel arch cover screws removed.

Pull back cover and tuck behind caliper.

Undo jubilee clip holding old filter in. (May also be a big tie wrap holding filter housing to bodywork so buy one in advance to replace it).


Remove old filter and joining pipe. Slip in new chrome joining pipe (supplied by Mango's) and new filter and retighten jubilee clip.

30 minute job, and it took Mangos 2 days to send me the new filter and pipe when I told them my old one was rusting.
 
#16 ·
Jack the car up and remove the wheel. You will see that the wheel arch liner is screwed in by a series of screws mainly one either side. Start at the bottom front of the liner with the two you can see there and unscrew all that you can see working your way up either side of the liner until after you have either 6 or 8 off, (probably better with 8) you can peel the liner back and bending it, clip it behind your brake caliper to hold it clear or, if you wish remove all screws and remove it completely.

The filter is now visible in front of you. The big shiny chromed band you see around its base is a Jubilee clip which can either be undone with a screwdriver or a small socket (unsure what size it was but around 8 - 6mm rings a bell). Once unscrewed and slack the filter just slides off. Simples!

Best of luck. :)
 
#17 ·
thanks Marzy. One clarification though.... what about the 'Smaco sport' tubing that is shown attached to the new filter in the pic at the start of this thread? i can see that the old filter is attached using a jubilee clip to the existing short section of tubing.. but if I am replacing the old filt + old tubing with the new ones, how do I remove the old tubing?
Thanks.
 
#18 ·
When I looked at my K&N after Mangos had fitted it,it was held in place with tie-wraps as well.Presumably to stop vibration and rattles.A bit Heath-Robinson I have to say.Next time I check it I'll take a photo.I actually thought of putting the original box back and having a K&N replacement filter,mainly because I was worried about water ingress under the arch.I couldn't see the inlet securing bolt holes from the arch,so assume the bumper came off to remove the original airbox and trunking. Trouble is I like the induction noise too much! Hesitation is still evident dependant on ambient temperature.
 
#21 ·
Hi Simon, where do you get that figure from? I've not seen that anywhere, although I can quite believe it.

I swapped filters at the weekend and I'm not convinced by the results. The car doesn't seem as willing as it was and the noise is definitly less than before (the sound being the main selling point IIRC).

Looking at the old and new filters side by side (see attachment) I would guess that the new one has only about a third of the surface area of the original and my gut feel is this is not sufficient.

Cheers,
John
 

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#22 ·
Hi John.

Check my Brera V6 filter options thread.

http://www.alfaowner.com/Forum/tuning-and-upgrades/236666-brera-v6-filter-options.html

I used the P/N off the replacement Mangos gave GTleigh and went on the K & N site. The state only rated to 160bhp.

FWIW, GTleigh ditched his and went back to a standard airbox with a K & N cylindrical panel filter inside:)

To note, I am not trying to discredit Mangos despite the way they treated me - I'm just giving you the facts.
 
#23 ·
Looking at the side by side pics Mediaman has posted, am not conviced the proposed K&N filter will do the job or at least match the original Mod4 filter due to reduced surface area, unless somehow the K&N manages to let the same quantity of air due to reduced resistance to air flow (better or more permeable filter material?)....
I find it a bit confusing and dissapointing that Mangoletsi have not provided clarification to the discussions in this thread and justify why their K&N filter would work as designed for Mod4. Without technical details it would seem like the K&N replacement was picked randomly! Comon Mango... give us some details and explain the change........
 
#25 ·
I fitted a much larger pod filter, The car had less power low down and i went back to stock. i felt i was getting way too much air and the ECU couldn't cope. It sounded very loud, and i was worried about water and dirt. I think there could be a much better air intake mod, but it would need a new unrestricted inlet using colder air from the front. I believe SR felt he was down on power as well with the pod filter. Maybe just a K&N replacement filter is the way to go instead.
 
#26 ·
My car will be reverting to a standard intake with the Autodelta free flow filter in tomorrow.

Already booked Bumper Boy's (AKA GTleigh's) services for Sunday:)

As Kanga says, too much air upsets things.
 
#27 ·
I,too,began to feel the replacement K&N was a bit asthmatic-too small-so yesterday it was off with the undertray,wheel arch liner,front bumper and I put back all the standard gubbins,including the paper filter.It feels better and smoother.No induction noise but more driveable.I didn't realise the standard air intake trumpet was so high up and in front of the radiator to take in cold air.I think like SR that a K&N replacement is the way to go at the next service.Mangos clearly didn't do enough groundwork with the replacement cone.As someone has pointed out before,the original airbox shows evidence of grit and water ingress into the wheelarch,so I do wonder about the wisdom of replacing it with a cone filter in that position.
No sign of rust on the discarded cone after nearly 4000 miles,though.As its rated up to 160bhp I'll see if I can work out a way to use it on the wife's 2.0 litre 147.
Otherwise,all I'm left with for my money is the fuelling tweak.....
 
#32 ·
Have you got any pics of re-installation of the standard filter?. Am beginning to think that I should not bother fitting the K&N replacement Mangos have sent me. The car doesnt feel happy to drive low down with the existing Mod4 filter and fuelling tweak! Initially it felt good but once the car settled down it has become progressively worse!! Am not sure how the original filter and tubing fits..... help!
 
#30 ·
Reversion done - thanks Leigh:thumbs:

Also done an ECU reset and the car drives great:wow:

Much more rounded, stacks more low down grunt but less roar, especially at the top end.

Much happier overall so no more silly cone filters - lesson learned:)
 
#33 · (Edited)
The reversion is going well. The car feels re-born this morning. So much smoother with none of the rough holding back it was doing when cold:)
 

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