1.6 hdi air filter box mounting bushes

[PaulC5]

Our 1.6 hdi Cactus started becoming noisy under the bonnet and I found the back of the air filter could be lifted about 1 inch so was banging about. Apparently this is common as the mounting rubber bushes wear through. This U-tube video shows what is involved in replacing the bushes, part no. 1623159380, £18 for the 4 bushes from a Peugeot dealer .

It was a pain though as I could not remove the small pipe top right that connects to the box cover nozzle so could only move the cover to one side (I always did this anyway when replacing the air filter) so the lower part of the filter box could not be extracted or moved enough to give much space. I managed to replace the front and left rear bushes (looking from the front) with a bit of washing up liquid so they slipped easier into their holes. To do the right rear one was not easy and would not go in its hole due to lack of hand space and I nearly dropped the bush down the back of the engine so in the end had to remove the pipe from the cover. Whilst doing this the nozzle on the cover broke off leaving it in the pipe. With the cover removed the lower box was easy to get out and then I found the bush could easily be slid sideways into its hole as there was a cut out which I wrongly thought was damage - if I had known this the cover and its pipe did not need fully removing. A right side wiring clip was also difficult to undo until I found sliding a small screwdriver down the back of it released its cover.

I managed to get the cover nozzle out of the pipe using force/pliers/a small screwdriver to lever out its side clips. Using Loctite All Plastics super glue I stuck the nozzle back and once set put silicone sealant on as well in case of air leaks. The pipe then clicked back in place and so far has been ok and not broken off. In the video you can see the cover nozzle is also broken off and this seems to be common as when looking at used filter boxes the connection is broken off on many. Used ones are around £60 but new from a dealer well over £200.