CJAA intake manifold ideas

v8 coupe

Veteran Member
Joined
Sep 3, 2008
Location
bloomington, mn
TDI
09 rabbit 2.5L Gas
I don't really see much discussion on this really anywhere so I figured I'd ask.

I know the Swirl flap delete is a hit and miss if people like it or not, but I have a question about the insanely jumbled intake manifold as an assembly.

Has anyone looked at updates/upgrades to this? I know that's a discussion for other engines (ALH, BEW, 1Z, etc), not here. What makes me think of this is the intake horn on my 6.7L Cummins the factory one works fine to well over 1k hp. Gale Banks has a bolt on replacement that, because he made 1 new fuel line to reroute it improves flow by 78%.

I'm wondering if something better than stock is possible assuming flap delete and tuning are already on the mod list. I understand there aren't many options for this out there, but these days that's a minor inconvenience I feel.
 

Bigtoy302

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Dec 20, 2016
Location
Eugene, OR
TDI
CJAA swapped Tacoma
I don't think you'll see any gains unless going for big power like 500+HP. It doesn't look like much of a restriction. I plan on making a billet one for my big compound build because I can and want to delete the swirl flaps lol.

I'm also building a engine dyno so I can do lots of testing on these CJAA's because nobody is really pushing them. I want to test all kinds of stuff like the intake manifold, stock vs ported head, cams, different compound setups. I'm building a CJAA now and trying to go past the 500hp mark fuel only.
 

v8 coupe

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Sep 3, 2008
Location
bloomington, mn
TDI
09 rabbit 2.5L Gas
That still to me doesn't look like much if any improvement over a deleted CJAA unit. I feel there is potential for a better solution, though I feel it may like on the Cummins require line work. I can see the end 2 cylinders being limited on flow from the turbulence the odd shaped plenum creates.

That's what the Monster Ram intake horn does by moving the fuel line out of the way the improved geometry actually out flows a straight pipe in. I'm definitely not going to go to that level, I just think something better might make a huge difference.

I'm not really thinking peak power is where the improvement would be it's really in the low rpm, low boost I'd like to improve it. I don't really understand why a 16v CR 2.0L can't do ALH like mileage. Is it purely from the reduced compression ratio or is it a non optimized execution?
 

txxander

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Jan 31, 2025
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Central Texas
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2012 Golf TDI DSG
I appreciate this thread every 2-3% here and there adds up quick. That's why banks does so well in my opinion.
 

TurboABA

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Jul 24, 2010
Location
Kitchener, ON
TDI
RIP-2010 Jetta 6spd 2014 Touareg Execline '14 A6 Technik S-line
I don't really understand why a 16v CR 2.0L can't do ALH like mileage.
According to who\what?
Sure it can... strip all the emissions crap off it, optimize it for FE instead of emissions, dump it in a similar weight chassis, and be amazed!
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
You have to remember, fuel economy and EPA-friendly emissions are at odds with one another. Why do you think they made Volkswagen buy back and crush a bunch of 45+ MPG cars, yet the 30 MPG versions (let alone all the pump-sucking gasser T-regs, big Audis, etc.) are safe from this?
 

calimustang

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May 17, 2010
Location
Central FL
TDI
2011 JSW DSG (buyback, RIP), 2014 JSW TDI, 2015 Passat TDI, 2013 Jetta TDI.
sheer stupidity imo.
You have to remember, fuel economy and EPA-friendly emissions are at odds with one another. Why do you think they made Volkswagen buy back and crush a bunch of 45+ MPG cars, yet the 30 MPG versions (let alone all the pump-sucking gasser T-regs, big Audis, etc.) are safe from this?
 
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