Modifications to my 2003 PT Cruiser Air Intake Box
Here's how I modified the stock air box to allow a little bit more airflow through a new K&N high performance drop in filter replacement.
First, I took out the box, not too hard, but you do have to put a little muscle into it, especially since it was about 25 degrees F when I decided to do the job! Gentle rocking motion, and plenty of lifting finally got it to pop loose. Here is a shot of the original airbox and "snorkle".
Next I had to modify a 3" Street L (90degree black plastic drain fitting) by cutting it to leave about a half inch left of the smooth tip, and cutting the other end off above the flared fitting.
Then I modified a rubber reducer fitting, a 3" X 2" flexible coupler by cutting it similarly, leaving about a half inch for each end to accept the stainless steel clamps that came with it on the outside.
(Be VERY careful in cutting these parts with a table saw, or a crosscut saw, cut slowly, and don't let your saw grab the part and pull you with it! Safety first with power tools!)
Here's a pic of one, I cut it just inside each of the clamp recesses:
I cut off the "snorkle" as close to the box as I could to leave the fitting on the outside of the box intact, but getting rid of the reduced part of the snorkle pipe. This expanded the opening by at least a quarter to a half of an inch in the radius of the pipe, allowing a greater volume of air to pass through. I cut the other end of the pipe sticking into the airbox at an angle, so that it would still offer a little protection from any water that might get sucked into the intake pipe. I then slipped the cut Street L into the large end of the rubber coupler and clamped it on (probably not necessary, it was a tight fit, but, I had the clamp anyway..... Next I found I had to modify the smaller end by using my Dremel with a grinding bit to remove about half of the thickness of the rubber all around the inside of the opening. (I might have been able to slip it on, if I had softened the end of the fitting in hot water.) I slipped that end onto the lip of the opening on the box, and tightened the clamp onto it. I then test fitted the contraption, and after a couple of tries, I got the length of the plastic pipe to where it sat just above the opening in the fender. I left about 1/8" to 1/4" of a gap between the fender well and the pipe.
This set up practically covers the whole opening in the fender. I plan to put some self adhesive foam rubber strip insulation around the tip, so that it only allows cold air from the opening through the intake pipe.
The final product looks like this:
I popped the box back into place, then I removed the white silencer in the box cover, and put in a K&N High Performance drop in replacement filter. (Here's a hint, remove your wrist watch... Seems I tried to weld my watchband to my wrist when it made contact with the exposed ground connection on the battery... live and learn!)
After putting it all back together and firing it up, I'm quite pleased with the beautiful sound of the engine, and it has much better acceleration and response. My 2003 PT Cruiser Limited Edition is an automatic, and I need all the help I can get! It sounds so good, and responds so well, that I couldn't tell you yet if it has improved my gas milage, because I can't stop puttin' my foot in it!
The speed limit may be 65 mph, but it doesn't say how long it should take you to get there!
Mods so far - This one of course, then: PICS
TYC Euro look back up lights
Molded rear mud flaps
Logo chrome valves stem caps
Rally Billet door lock pins, and a few fun magnetic flames, bullet holes, and stickers.
Chrome grill kit
1940's style chrome front fender strips
Chrome E & G portholes for the sides of the hood
Chrome Gauge Eybrows
PT Logo valve stem caps
Flame gauge decals
I'm also very tempted to get some "Liquid Flames" 3D decals for the sides, I have a Lt Almond Cruiser, and I'm thinking of the Gold Ultra Metalic flames..... subtle but effective. But it may be a bit over the top. I'll have to wait and see what everything else looks like installed, then decide.
And I'd like to add a BTG exhaust system at some
time - 
After that, who knows?