Cabin Air Intake Screen Mod

Does your cabin air filter look like it belongs in the woods rather than your truck? Have rodents moved in and made their home in your A/C intake? I've got a cheap, effective solution for you. While I'm not the first to do this, I haven't seen a good write up for this mod. I spent about $7 for supplies + about 15 minutes (longer for me because I was documenting.)

Filter I found in the woods



Complete Cabin Air Intake Screen Mod



Tools you'll need:

1. Mesh roughly 12"x 5"- can be anything with "small enough" holes to keep your target debris/critters out. Examples - expanded metal, stucco grating, slotted metal, window screen, gutter cover. If you live in an area with pine needles, or other small detritus, use a "finer" mesh to keep it out.
2. Tin Snips
3. Measuring device
4. Needle Nose
5. Phillips Screwdriver
6. Hammer
7. Fingernail Polish
8. Hardware - M4 or M6 Bolt, nut, lock washer. You can also use zip-ties. Or tape/adhesive.

I used Amerimax Steel Gutter Guard from Lowes.

Lowes Part# 502138
Model # Amerimax Metal Lock-In Gutter Guard #6360

I liked this because it's metal, it's in a black finish to minimize rust, the holes are small enough to keep most things out, it's the right size without being wasteful and it's cheap - $3.28. Originally I was going to use aluminum window screen mesh but it cost $7 and was enough for 2 windows, which was way too much material for what I needed.

I used 2x M4 bolt, lock washer and nut. M6 will fit through the mounting holes in the body if that's what you have.



Cabin Air Intake Location & Cowl Removal

The intake is located on the passenger side (green box), underneath the black plastic cowl, adjoining the base of the windshield and the hood. There are two clips at either end (green arrows). You'll need the Phillips to remove these. Or they'll be so old that there will be one missing and the other on it's last legs and you can pull it out by hand (which was my experience).

Next undo the six plastic clips holding the cowl to the body (red arrows are approximate locations). Look underneath the weather striping and you'll see them poking through the body. Push these with a finger and pull up on the cowl to get them lose. Three are left of center, three are right of center. There is a center alignment peg (blue arrow) dividing left and right (you'll see it under there, but it shouldn't be bothersome).



Passenger Phillips Clip Close Up (green arrow)

Remove this and the one on the driver's side.



Push Clip Locations (Passenger Side)

6 push clips located under the weather striping and the lip on the top of the firewall. Push with a finger and pull up on the cowl.



Remove Debris (Optional)

Once cowl is lose, remove any leaves and debris that may be under there. Wipe with wet towel (Optional). I removed the debris and wiped it down since I had the opportunity.

Before:


After:


Prop Cowl

Use something to prop the cowl up so you can work under there. I used the head of a rubber mallet. You gain enough room to work without having to remove the whole cowl. We get our first glimpse of the cabin air intake.

You can also completely remove the cowl, which I don't go into with this tutorial - it involves removing both wiper arms.



Close-up cabin air intake

You can see directly into the intake and see the cabin air filter - slightly disconcerting knowing that a thin piece of plastic is all that is preventing the environment from getting in.

Also sad is the fact it looks like Toyota was going to put an outer screen/filter but decided nah, it's not necessary. There are mounting holes and everything.



Measurements

I'm including these measurements for anyone that needs to know the actual size of the intake opening and the minimum size mesh required.

Roughly 10.5" x 4.25". But the hole is tapered - narrower towards the middle of the vehicle, wider towards the edge.

Length



Width



Cut Mesh to Size

I cut the gutter guard down to 12"x 4.5", leaving the pre-bent end. It so happens that it's the perfect size to fit over the large lip.



Bend Straight Edge

I used a hammer and a sharp angled block (a stepping stone in this case) to bend the straight edge. You'll notice it is tapered to match the tapered intake slot. Around half an inch on the short edge, about 1.25 inches on the long edge. Once the bend is made, you can place the mesh over the slot for a rough fit.



Rough Fit & Cut Lines

I placed the rough cut mesh over the slot then used white nail polish to draw cut lines to better match the flange. I also placed the bolts in the holes and marked about a quarter inch on each side of the bolt to cut away the pre-bent section, so that the nut would fit underneath.

The pre-bent shape fits the large lip pretty well.



Cut and Bend to Fit

Make your final cuts. Place back over the intake slot and bend the sides down. You end up with something like this.



Paint Ends (Optional)

Use the finger nail polish to paint the ends where you made cuts. The exposed metal will rust. I used a dark blue, that's the darkest my wife had. She didn't have black, I guess she's not in a punk rock band. It's in an obscure place that no one will see, so it doesn't really matter what color it is.



Bolt It On

Attach to the mounting holes with bolts. Zip ties. Adhesive. Spread your wings, be your own modder!

Not this time leaves!



A Final Note

When you put everything back together, make sure the weather striping from the cowl to the base of the windshield is properly aligned. You'll *theoretically* get water leaking into the cab otherwise.

No, Bad



Yes, Good



TL;DR
Cabin Air Intake Screen Mod
Loosen Cowl at base of windshield and hood - 2 phillips clips, 6 push clips
Cut mesh of choice to size (roughly 12"x5"), bend, cut, bend, cut until happy.
Attach with hardware of choice.
Remember the good ol' days when nature lived in your cabin air filter.

For other Cabin Screen Mod Ideas:
Post #10,#12,#17
Post #1, #28

 

Spectacular write up!!

 

Good write up! I need to do this some day, along with the relocated rear diff breather mod.

 

Both are super easy! They are 20 minute jobs! Hardest part about the rear diff breather is removing the spare. Lots of space if you do it that way.

 

What a great idea, and super cheap. Thanks OP!

 

excellence!

 

what a pretty ass screen! lol looks like ill make one myself this week. thanks for the write up!

 

Well done!

 

Great Idea !!!

 

Nice write up!

 

Awesome write up

 

Adding to the list of things to do...

 

It's black and blue and fabulous isn't it? Make sure to post your results and any findings or input you have to make this better/ easier/ alternative way for others to make.

 

Maybe I'll try and do this this weekend. Thanks!

 

Awesome, I will be doing this ASAP.

 

nice job

 

Great write up OP!

 

OMG, You meshed it up big time.

 

QUOTE="knottyrope, post: 18626751, member: 216122"]OMG, You meshed it up big time.[/QUOTE]
That's good material...

 

When i bought my used ‘08 Taco, one could have reassembled a good sized willow tree with the leaves on top of my filter!! Good idea here!!