v8 coupe
Veteran Member
Well Being as I'm just starting down the slippery slope of moddin' my 03 TDi golf I bought a new intake manifold and wanted some opinions on what every one thinks of my purchase.
The manifold is off a 89' or 90 (89 build year) Cabrio with digi I plan to install this intake along with a large FMIC later this year so I fiugred since I have my head off for some work I'd mock everything up and getting it setup for a direct drop in later on with no surprises.
First test fit and it looks really really good. I had to remove the top stud of the EGR, but since this manifold would require an EGR delete a short cap screw could be fit with removal of the large fin on this intakes back side
EGR boss clearance
Biggest issue with this manifold is how small the intake ports are. They are in a place that can be made to work on the TDI and it's almost a straight shot out of the runners down the intake port so it should flow some serious air. I'll have to weld some material in on the flage area of the manifold to give me enough material to have a flange left once this thing is hogged out to gasket size. I know there are a few manifolds like the G60 people like better, but this thing was CHEAP and fits pretty good right out of the box.
Ports:
and a look into the Plenum which looks to have some nice big rediuses on it for good flow.
My current plans are to get the manifold cleaned then bead blast the thing clean. I'll then use a series of flew hones and flexible paper flap sanders to polish the entire runner before hogging the flange area out to gasket shape since the current shape is easier to hone. I'll then polish the end back up with a similar process and make an adapter plate to go from the stock TB shape to a 2.5" round for the inter cooler piping. My goals for this car are to take the stock turbo as close to 150HP as possible and I think a much freer flowing intake will greatly help this. I know it will make removal and install a little tricky, but I have dealt with similar issues on my other project car where I am dropping a 4.2L v8 in a Audi coupe it makes everything harder.
The manifold is off a 89' or 90 (89 build year) Cabrio with digi I plan to install this intake along with a large FMIC later this year so I fiugred since I have my head off for some work I'd mock everything up and getting it setup for a direct drop in later on with no surprises.
First test fit and it looks really really good. I had to remove the top stud of the EGR, but since this manifold would require an EGR delete a short cap screw could be fit with removal of the large fin on this intakes back side
EGR boss clearance
Biggest issue with this manifold is how small the intake ports are. They are in a place that can be made to work on the TDI and it's almost a straight shot out of the runners down the intake port so it should flow some serious air. I'll have to weld some material in on the flage area of the manifold to give me enough material to have a flange left once this thing is hogged out to gasket size. I know there are a few manifolds like the G60 people like better, but this thing was CHEAP and fits pretty good right out of the box.
Ports:
and a look into the Plenum which looks to have some nice big rediuses on it for good flow.
My current plans are to get the manifold cleaned then bead blast the thing clean. I'll then use a series of flew hones and flexible paper flap sanders to polish the entire runner before hogging the flange area out to gasket shape since the current shape is easier to hone. I'll then polish the end back up with a similar process and make an adapter plate to go from the stock TB shape to a 2.5" round for the inter cooler piping. My goals for this car are to take the stock turbo as close to 150HP as possible and I think a much freer flowing intake will greatly help this. I know it will make removal and install a little tricky, but I have dealt with similar issues on my other project car where I am dropping a 4.2L v8 in a Audi coupe it makes everything harder.