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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old May 21st, 2011, 20:16   #1
Fix_Until_Broke
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Default SDI Intake on ALH with Dyno Data

I modified my turbo and SDI scroll style intake manifold to bolt on in place of my ALH intake manifold. I use my EGR port for measuring EMP's so I modified the stock flange on the turbo a little to accomodate the larger intake. You also have to remove the OEM TIP heat shield on the right side of the manifold to get the intake to clear the exhaust manifold.











I tapped the EGR hole to accept a 7/8-14 UNF bolt to be able to plug it off. Unfortunately, I didn't check to see if I had a 7/8-14 UNF bolt to put in the hole....so I found a 3/4 to 1/8" NPT bushing and it threaded in the hole "well enough" for the time being.

I used a ~2" hole saw and drilled the right side of the manifold out centered in the steel plug. I then spent some quality time at the TIG welder welding over the raw cast aluminum with no filler over and over again to get all the impurities out before I could finally add filler and build up a boss that I then ground flat. I then drilled/tapped with the pattern from my race pipe. I made simple steel block off plates for all the other holes and screwed a 3/4" NPT plug in the CCV port. All of this work makes it "interchangable" with the stock ALH intake and racepipe. I drilled/tapped the original inlet blockoff plate for my boost gauge connection.





Pretty clean install if I do say - the upper engine cover mount does not line up but you'd never know it. I had to make a ~3" long extension to make the OEM question mark shaped hose fit since the SDI sits farther "back and down" and I had to bend the high side A/C line out of the way (which I ended up breaking - doh!).



I only had to rotate the 45deg bend at the top of my 3" TIP to make it work (and it still works with the ALH intake as well).



I took the opportunity at the recent local dyno day to do some dyno testing between a stock ALH intake and an SDI intake. The runs were made on the same day about 1 hour 45 minutes apart with the same tune, etc. The SDI was run first, then the ALH. I'll let the results speak for themselves.



copy/paste of signature for reference

03 Jetta, Cat 2u Fuel Filter, DG Steel SP with MOGolf Mod, DG Ultra SS, 3" downpipe, 4" exhaust, CC Vent, 0.681 5th, Amsoil EaBP110 Bypass, Elf 506.01, Redline D4, Boost & EGT & EMP & N75 Gauges, Euroswitch, PD Lift Pump, EGR Delete, PP502 DBW'd, RC5 or 6, ScanGaugeII, BB Dual Diaphram Clutch, 3" Turbo Intake Tube, VNT 17/22, 3 Bar MAP, VR6 MAF, Vented Fender Liner, Battery Cover Access Mod, 11mm IP, Monster Mats, 205/70/15's (27.9/53.0/75) Monthly MPG Links, Euro Trunk Latch, IDParts RSB
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03 Jetta, Cat 2u, DG Steel SP w/MOGolf Mod, 3"DP, 4"EXH, EaBP100 Bypass, Euroswitch, ECodes, Driving Light, PD Lift Pump, R520's, RC5,RC6, TDTuning, Malone, ScanGaugeII, 3" TIP, 2" TOP, HE221W Compounded with GTC1444VZ, 6 Bar MAP, VR6 MAF, Vented Fender Liner, Battery Cover Mod, 11mm, Monster Mats, 215/55/17 (27.9/53.0/75) Monthly MPG Links, Euro Trunk Latch, IDParts RSB, SDI or ALH Intake, ARL Ceramic Pistons, Rosten Rods, DRW, Wavetrac, SBC, FSD's, Beef Springs, Rebuilt Head, Recaro's, Colt II, DG Sigma 6, RMT200

Last edited by Fix_Until_Broke; May 21st, 2011 at 20:55. Reason: Added copy/paste of signature to reflect modificatins at time of testing
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Old May 21st, 2011, 20:42   #2
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Sooo.... stock is better? Really?
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Old May 22nd, 2011, 01:41   #3
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Great test results maybe test the pd130 intake also
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Old May 22nd, 2011, 01:49   #4
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I would have thought that an audi A4 pd130 intake with input on the rhs, which has been ported would provide a reasonable increase in flow.......
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Old May 22nd, 2011, 02:08   #5
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hah!
I thouth that SDI intake is the best intake ever...so guys if you want to rerach 250+hp, ALH intake is your manifold
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Old May 22nd, 2011, 02:19   #6
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Wow, I have difficulty comprehending the results if everything is as "even" as it seems for the testing.
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Old May 22nd, 2011, 05:22   #7
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Wow! Did not think that would happen!

And you are only making 125 whp on RC5?
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Old May 22nd, 2011, 06:23   #8
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Wow So What about the PD150 With the R32 Snorkle and TIP kit?
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Old May 22nd, 2011, 07:20   #9
Fix_Until_Broke
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It's not what I expected either - I figured I'd take the best and worst looking bolt on intake manifold designs and compare them. I'd expect the PD130/150 intakes to be somewhere in the middle, but maybe not?

The power numbers are lower than I expected with a 11mm pump/PP502's/lift pump/17-22/full IQ voltage/etc. I know my stock intercooler and pipes are not the best, but I don't think they're that bad either where they would cost 40hp? That's a whole different discussion though.

I reviewed the VagLogs and dyno data and nothing stands out there that would make a difference. I triple checked the data to make sure I'm comparing the right files, etc.
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Old May 22nd, 2011, 07:24   #10
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Quote:
Originally Posted by JarHead View Post
Wow So What about the PD150 With the R32 Snorkle and TIP kit?
I don't have any of those specific items to test with, however, I'm running a VR6 MAF housing, no snorkle on the airbox at all and the pictures show my 3" mandrel bent TIP. These items were the same for all the testing.
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Old May 22nd, 2011, 08:00   #11
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Were you able to collect any intake air temp data from the 2 runs?
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Old May 22nd, 2011, 08:27   #12
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I have ordered a complete R32 Snorkle back TIP kit as well as a PD150 Intake From Ryanp. I will get it Dyno'ed with a before and after. Ill let you guys know.
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Old May 22nd, 2011, 08:38   #13
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Quote:
Originally Posted by O.C.TDI View Post
Were you able to collect any intake air temp data from the 2 runs?
x2

With 1hr 45min between runs, heat soak should not be an issue, but did ambient go up significantly. It does seem a bit counter intuitive.
I think this speaks about a bigger issue. Members are spending lots of money on items that have questionable performance value. When I say questionable, the product may be of excellent craftsman ship, or is great looking OEM part, and it may or may not add HP, but where is the data too show it actually has done anything positive. It would be nice if people pedaling parts would do some dyno testing on them before asking others to waste their hard earned cash on the perception that it is a performance upgrade.

thanks for your work on this FUB.
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Old May 22nd, 2011, 08:40   #14
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Quote:
Originally Posted by JarHead View Post
I have ordered a complete R32 Snorkle back TIP kit as well as a PD150 Intake From Ryanp. I will get it Dyno'ed with a before and after. Ill let you guys know.

Sounds like an intake sticky in the making.
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Old May 22nd, 2011, 08:54   #15
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Congratulations on a very nicely documented test!

This is the type of testing the factory does on each and every part to come up with their stock engines. That is why it is so hard to improve on the factory and to make it last for the lifetime of the car.

Many years ago, I had the chance to review a whole series of documented Chevrolet dyno development tests of the old Corvair high performance engines. Very enlightening to see all the tests the factory does before releasing a production engine.
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