ECS Tuning 1.8T/2.0T Gen3 Aluminum Intake Manifold Kit

OVERVIEW

The ECS Tuning Fabricated Aluminum Intake Manifold for the VW / Audi 1.8T /?2.0T Gen3?engine?provides?even air flow distribution to all four?cylinders due to its 53% larger plenum volume over the stock manifold, parabolic velocity stacks and reconfigured plenum geometry.?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 balanced airflow and could increase top end charge to maximize your engine's efficiency.?

The OEM plastic intake manifold suffers from cylinder imbalance by up to 5% between runners. The result is uneven cylinder filling within the outer runners and would likely cause variations in air/fuel ratios which could create dangerous conditions! Our intake manifold?equalizes this flow imbalance without sacrificing any efficiency, providing a flow balance deviating less than 0.5%. In addition, our manifold eliminates the factory air dividers. We recorded an airflow?increase of up to +8% CFM over the factory 2.0T Gen3 intake?manifold.?

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?5-Axis 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.?In addition, our manifold was engineered with provisions for auxiliary port injection fueling for those looking to make serious power. Optional blockoff plugs are a standard option for those not utilizing dual fuel injection.?The 5052 aluminum sheet plenum houses the billet velocity stacks, while increasing plenum volume 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 in-house engineering team in our Wadsworth, Ohio facility. All fabrication, final assembly and quality inspections?are done right here in the U.S.A.!?

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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. Our manifold blocks off the integrated PCV return port through the cylinder head. ?We recommend the use of our ECS Tuning catch can, however, it is not required and the factory PCV system will still operate without adverse affects. The factory engine cover is not compatible (without trimming) due to our larger plenum volume.?

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PART DESIGN

Cylinder Head Flange:

• 5-Axis CNC machined from 6061 aluminum?

• Machined O-ring grooves?secure the included individual Buna-N O-ring seals?

• Integrated injector bosses for optional port injection?

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Intake Runners:

• 5-Axis 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 pre-machined 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:

• 5-Axis CNC machined from 6061 aluminum

• Features parabolic velocity stacks which?provide smooth airflow into each intake runner

• Relocated MAP sensor flange for a cleaner appearance?

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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 promoting consistent cylinder filling

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?Throttle Body Flange:

• CNC machined from 6061 aluminum?

• 70mm throttle body opening; features a radiused outlet for smooth airflow entry into the plenum

• Compatible with OEM throttle body

• Incorporates NPT vacuum ports in front and passenger side locations

  • Various pipe plugs and nipple fittings are included to accommodate custom setups

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Port Injection Accessories:

• Port Injection Block-Off Hardware Kit (standard)
  • Base option, retains OEM fueling hard parts?
  • CNC machined aluminum, black anodized blockoff plates with O-ring seals?plug the optional additional injector bungs?
• Port Injection Hardware Kit (optional)
  • Upgrade option, permits the use of aftermarket / ROW (Rest of World) port fueling kits
  • CNC machined aluminum, black anodized injector cups with O-ring seals adapt common OEM and aftermarket fuel injectors into the manifold ports?
  • Machined lock plates (optional) to secure injector cups?
  • 5052 aluminum, black powdercoated fuel rail bracket positions the ROW fuel rail bracket in OE location
  • Verified compatibility with APR Stage 3+ Fueling System Upgrade and CTS Port Injection Kits?

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Accessories:

• Compatible with OEM?harness connectors and coolant hard lines
• Eliminates OEM head flange and throttle body gaskets. Uses easily serviceable oil resistant Buna-N O-rings.

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Final Assembly:

• Available in a raw machined finish or a wrinkle black powdercoat finish

• Fabricated, TIG welded?and formed?in the U.S.A. by expert fabricators

• Tested to 0% leak down at 3 BAR for final quality?

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INCLUDED KIT CONTENTS

• Intake Manifold Assembly

• Intake Runner O-Rings - QTY 4

• Throttle Body O-Ring - QTY 1

• All new mounting hardware packs

  • Intake manifold mounting bolts (10)

  • Throttle body mounting bolts (4)

  • MAP sensor mounting bolt and washer (1)

  • Coolant hardline mounting bolts (2)?

  • Wiring harness mounting bracket bolts (2)?

  • Assorted sizes of brass NPT to nipple fittings and block-off plugs?

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PERFORMANCE FEATURES

• ?Our intake manifold provides?even air flow distribution to all four?cylinders due to its 53% larger plenum volume over the stock manifold, parabolic velocity stacks and reconfigured plenum geometry

  • Stock 2.0T Gen3 plenum volume: 81 in.? (1.33 Liters)?

  • ECS plenum volume: 151?in.? (2.47 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 in-house Superflow Flow Bench we recorded +3 to?+8% increase in CFM over the factory 2.0T Gen3 manifold. 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 5% between runners. This results in uneven cylinder filling within the outer runners and would likely cause variations in air/fuel ratios which could create dangerous conditions! Our intake manifold?equalizes this flow imbalance without sacrificing any efficiency, providing a flow balance deviating less than 0.5%.

• Does not incorporate runner 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 leading-edge product development technology including FARO laser scanning for reverse engineering and quality inspection, SolidWorks 3D CAD modeling, rapid prototyping utilizing our in-house 3D printer, and rigorous long term product testing.

• Performance data metrics were collected utilizing our?in-house Superflow SF-750 Flowbench.?

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INSTALLATION AND SUPPORT

??Our intake manifold was designed to accommodate most OEM features and to provide a bolt-on installation.?However, due to the nature of this product type it requires modification of several OEM parts, custom ECU tuning, supporting modifications and professional installation.?

Custom Tuning:

• Please check with your software tuner prior to purchasing. Our manifold removes the runner flaps. This WILL cause a check engine light and rough cold starts at cooler temperatures. Your software tuner will need the capability to remove the error code and remap your ECU for cold starts without the runner flaps. As noted above, bolting on our manifold will not create an impactful increase in power without custom?software tuning to maximize the benefits of our part.

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Supporting Modifications:

• In order to maximize the benefits of our intake manifold you must have a larger frame turbocharger, improved intercooler, freer flowing intake and exhaust upgrades and custom ECU software tuning. Our manifold has been tested and verified to operate on stock engines. This manifold works best when combined with other supporting modifications.?
• Due to the large plenum design our ECS Tuning Engine Cover is not compatible.

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Modifications to OEM parts:

• PCV System: Our manifold blocks off the integrated PCV return port through the cylinder head. ?We recommend the use of our ECS Tuning catch can, however, it is not required and the factory PCV system will still operate without adverse affects.?
• Fuel Hose: You have the OPTION to route the HPFP feed hose (low pressure feed) over the runners, however, we prefer a cleaner appearance by routing this hose below the manifold. This is accomplished by adding length to the OEM hose or cutting the hose in the middle and extending the hose length. An optional fuel feed reroute kit is available separately.?
• The factory engine cover is not compatible (without trimming) due to our larger plenum volume. It is possible to trim the front vertical plane of the engine cover to allow clearance, if desired.?
• Not compatible with ECS Tuning Engine Covers.?

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Professional Installation:

• We recommend advanced skills and experienced technicians to install our manifold. Our Installation PDF will guide an experienced technician through the procedure, but this install is not for the mechanically novice. Please read the entire installation PDF prior to installing this part.?