OVERVIEW
The ECS Tuning Fabricated Aluminum Intake Manifold for the VW/Audi 2.0T FSI/TSI engines provides?even air flow distribution to all four?cylinders while increasing throttle response due to its 53% larger plenum volume over the stock manifold. If you've upgraded?to a larger turbo and you're looking to take your?build to the next level, then?the ECS Aluminum Intake Manifold is for you! This manifold is the perfect foundation for?improved throttle response, balanced airflow and increased top end charge to maximize your engine's efficiency.?
The OEM plastic intake manifold suffers from cylinder imbalance by up to 10% between runners. The result is uneven cylinder filling within the outer runners and variations in air/fuel ratios which can create dangerous conditions! Our intake manifold?equalizes this flow imbalance without sacrificing any efficiency, providing a flow balance deviating less than 1%. In addition, our manifold eliminates the problematic?and powerrobbing factory?runner flaps/air divider drive units. We recorded an airflow?increase of up to +8% CFM over the factory FSI and TSI manifolds.?
Our Engineering Team at ECS Tuning sought out to make the best intake manifold available on the market. Rather than designing a cast manifold, they took a different approach. This meant?engineering?a billet and fabricated aluminum sheet design, featuring?5Axis CNC machined aluminum mounting flanges and billet CNC intake runners. This design provides an?optimal flow path and smooth?transitions from the parabolic velocity stacks inside the plenum to the intake port shape. This allowed us to achieve the smoothest airpath possible which we favored over rough casting marks found from?traditional?cast designs. Our billet runners feature 1/8" NPT ports which are?ready for nitrous or water/meth injection nozzles. NPT pipe plugs are included for those not running power adders/post cooling devices. The 5052 aluminum sheet plenum houses the billet velocity stacks, while increasing plenum volume by 53% over the factory manifold for increased throttle response and improved cylinder filling.?
Our ECS Intake Manifolds were designed, engineered, tested and quality inspected by our inhouse engineering team in our Wadsworth, Ohio facility. All fabrication, TIG welding, machining and?forming are done right here in the U.S.A. by expert fabricators using U.S.A. sourced materials!?
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** CUSTOM TUNING AND SUPPORTNG MODIFICATIONS?NOTE: **
Please read ALL of the information in the description below the INSTALLATION AND SUPPORT header prior to purchasing.?Please note, bolting on our intake manifold by itself without further supporting modifications and ECU tuning will not result in more power with OEM sized turbochargers. We recommend our manifold to be used with a larger?frame turbo, a more efficient intercooler, freer flowing exhaust and intake?upgrades and custom ECU tuning to remove the intake runner check engine light, revise cold start maps and to?maximize the benefits our manifold can create. Due to the large plenum design and the removal of the front PCV port our intake manifold requires the following:
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PART DESIGN
Cylinder Head Flange:
5Axis CNC machined from 6061 aluminum?
Machined Oring grooves?secure the included individual BunaN Oring seals?
100% compatible with the OEM fuel rail, fuel rail bracket and injector wiring harness with no modifications or trimming required?
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Intake Runners:
5Axis CNC machined from 6061 aluminum to provide equal runner velocity and optimal interior surface finish
Designed to provide?optimal flow path and super smooth transitions between the plenum flange and head flange
Secondary fueling/cooling/nitrous nozzle bosses are premachined atop each intake runner for direct port water/meth injection or nitrous nozzles?
Pipe plugs are included to block these off
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Plenum Flange:
5Axis CNC machined from 6061 aluminum
Features parabolic velocity stacks which?provide smooth airflow into each intake runner
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Intake Plenum:
Formed from 1/8" thick 5052 sheet aluminum?
53% larger plenum volume (2.47 Liters) promotes even air flow distribution to each runner while increasing throttle response and consistent cylinder filling
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?Throttle Body Flange:
70mm throttle body opening; features a radiused outlet for smooth airflow entry into the plenum
Includes IAT sensor port and securing bolt
Minor modifications are required to FSI IAT sensor harnesses only, no cutting or splicing required. See Installation PDF for more information.?
Incorporates 1/4" and 1/8" NPT vacuum ports in front and passenger side locations
Various pipe plugs and nipple fittings are included to accommodate various setups
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Accessories:
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Final Assembly:
Available in a raw machined finish or a wrinkle black powdercoat finish
Fabricated, TIG welded, machined?and formed?in the U.S.A. by expert fabricators using U.S.A. sourced materials
Tested to 0% leak down at 3 BAR for final quality?
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KIT CONTENTS
Intake Manifold Assembly Raw Finish
Fuel Rail Standoffs QTY 5
Intake Runner ORings QTY 4
Throttle Body ORing QTY 1
Various 1/8" NPT and 1/4" NPT Barbed Fittings and Pipe Plugs
All new mounting hardware pack?
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PERFORMANCE FEATURES
?Our intake manifold provides?even air flow distribution to all four?cylinders while increasing throttle response due to its 53% larger plenum volume over the stock manifold.
Stock FSI plenum volume: 81?in.? (1.33 Liters)
Stock TSI plenum volume: 81 in.? (1.33 Liters)?
Provides the necessary foundation for supporting modifications such as a larger turbocharger, more efficient intercooler and freer flowing intake and exhaust upgrades, along with custom ECU tuning.
Tested on our inhouse Superflow Flow Bench we recorded +3 to?+8% increase in CFM over the factory FSI and TSI manifolds. Particularly runners #1 and #4 found +6?to?+8% increase?in airflow by up to 15 CFM.?
The OEM plastic intake manifold suffers from cylinder imbalance by up to 10% between runners. This results in uneven cylinder filling within the outer runners causing undesirable variances in air/fuel ratios that can create dangerous conditions! Our intake manifold?equalizes this flow imbalance without sacrificing any efficiency, providing a flow balance deviating less than 1%.
Removes the runner flaps / air guides for improved airflow?
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PRODUCT DEVELOPMENT
Our ECS Fabricated Aluminum Intake Manifold?was designed, engineered, tested and quality inspected by our Research and Development team in our Wadsworth, Ohio facility. After several design iterations, multiple prototypes and multiple vehicle test fitments we are proud to offer a truly remarkable intake manifold to the VW/Audi market!?
We strive for the highest level of precision and quality through leadingedge product development technology including FARO laser scanning for reverse engineering and quality inspection, SolidWorks 3D CAD modeling, rapid prototyping utilizing our inhouse 3D printer, and rigorous long term product testing.
Performance data metrics were collected utilizing our?inhouse Superflow SF750 Flowbench.?
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INSTALLATION AND SUPPORT
??Our intake manifold was designed to accommodate most OEM features and to provide a bolton installation.?However, due to the nature of this product type it requires removal of several OEM parts, custom ECU tuning, supporting modifications and professional installation.?
Custom Tuning:
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Supporting Modifications:
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Required Modifications:
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Professional Installation:
