PD 150 Intake On stock Alh

[srt-kapp]

Hey, I Recently Purchased a Pd 150 intake (AF) and I want to put it on my 2003 Jetta Tdi Alh ( all stock). Can someone offer me some advise on making it work with stock intercooler piping?
Can I buy a 57mm egr delete race pipe and buy a 57mm 90° elbow that reduces down to 51mm ?

I just want a little insight so I don't waste my money.

Thanks

 

[panthers89fan90]

.

Hey, I Recently Purchased a Pd 150 intake (AF) and I want to put it on my 2003 Jetta Tdi Alh ( all stock). Can someone offer me some advise on making it work with stock intercooler piping?
Can I buy a 57mm egr delete race pipe and buy a 57mm 90° elbow that reduces down to 51mm ?
I just want a little insight so I don't waste my money.
Thanks

A few questions.

Do you plan to keep it stock?
You said your car is all stock? I'm guessing that means you have all your EGR plumbing still in tact? The easiest way is to buy the Pd150 egr and egr to intercooler hose. Ryan P from Darkside can hook you up with a used one for a decent price. Or if someone is selling one on here. You can't just buy the race pipe without deleting your egr valve. If you were to delete the egr valve, you would also need a tune to get rid of the CEL that comes along with deleting the EGR valve.

In all honesty though, I wouldn't put a Pd150 intake onto a stock car. You will see ZERO gains. I don't think it's worth the time until you're pushing more fuel.

 

[srt-kapp]

I'm sorry I forgot to add that I have a egr delete and cooler delete on my car now. I also have 2.5 exhaust too. But yes I plan on going with a bigger turbo and injector nozzles but I have the intake now and currently it's more cost effective to start with that since it's in my hands and then build from there.

 

[flee]

I made my own pd150 race pipe but if that is more than you want to tackle then
sourcing one from RyanP and using a reducer will work for now.

 

[panthers89fan90]

I'm sorry I forgot to add that I have a egr delete and cooler delete on my car now. I also have 2.5 exhaust too. But yes I plan on going with a bigger turbo and injector nozzles but I have the intake now and currently it's more cost effective to start with that since it's in my hands and then build from there.

Okay. Knowing that, I would either get the Pd150 race pipe from Darkside (Ryan P) or build your own. I have the race pipe from Darkside and it is purty. Shiny too!

To answer your other question, Darkside could get you the silicone hose to go from race pipe to upper intercooler pipe.
Click here for that hose.

I would suggest t-band clamps instead of worm gear.

 

[Kraiger]

Darkside hose is the way to go. But if you in a pinch you can heat the stock one and shove it on the PD150 race pipe.

 

[srt-kapp]

That's great advise thanks everyone for your imput. I ordered the parts minus the 57mm race pipe. I will try to buy one tomorrow or find a way to make one

 

[03tdijwagon]

I'm looking at doing the same thing and my car is stock now, but will not be when the intake manifold is installed. What air intake is best used with this up to 250whp? Any and all help is welcome.

 

[srt-kapp]

My current setup now. Is the pd 150 intake, custom upper intake pipe, With a big side mount intercooler. Race 520 nozzles ,vnt17. I like how it is. I'm on the stock map also. I need to get a tune but always debated on who to gi with. I do want to get the most fuel economy out of it also

 

[Andyinchville1]

My current setup now. Is the pd 150 intake, custom upper intake pipe, With a big side mount intercooler. Race 520 nozzles ,vnt17. I like how it is. I'm on the stock map also. I need to get a tune but always debated on who to gi with. I do want to get the most fuel economy out of it also

Hi

You've done what I'm heading towards... how is your current fuel mileage vs stock (of course assuming when you drive the car in a similar fashion).

I like your thought about trying to get max mpg in a car that can make good power over stock....

FWIW my fuel mileage stock with malone stage 1 tune was about 46 to 49 mpg in the driving I do.... after 11 mm pump and dlc 520 injectors only had 2 tanks under 50 mpg out if 16k miles and typ average about 52 mpg.

I'm hoping after I get the manifold on (looking at intake pipes also while its apart) to get maybe a little more mpg?

Thanks

 

[Mongler98]

I'm within a similar setup with pd150 on my ahu. 764s and a large 2052 turbo. Get great milage is I stay off it lol. Best I got was 62 cross country but 53 to 55 is typical if I commute on cruise control. But with the way i like to drive that car i get like 34mpg.
The pd150 is a great option to upgrade mile to heavy. Better flow across all 4 vs the stock. I would port match the intake runners to the gasket. Make a custom torque wrench. 12" bar stock bent to fit around the backside with a spring weight gauge. Pull it to spec torque. Its literally impossible to get a good torque on those bolts without adapters and that's sketchy. I had leaks after leaks until I got it back on with the head off so....results might vary. I did have to trim a small amout off the intake to clear the exhaust manifold but that's easy with a rounded file. I also made a race pipe to the stock pipes but if you have the $ get the right adapter imo. I have a build thread with my pd 150 called "look ma no veins" to lazy on my phone to find the link. I think it shows how I had to trim it to fit. Make sure you clean the intake ports on the head when you do this too. Dont want any crust falling into the engine. Some have totaled engines and heads from this so look out for that.

 

[ahldailydriver02]

I have 2002 jetta with Malone stage 1, DLC520 injectors, BRM intake, vnt 15 and stock exhaust, driving 65-70 mph with some mixed in town driving I average 45mpg. I think I could get better if I would have it re-tuned.

 

[KCTDI]

I used the adaptor from Malone and used the stock EGR (in stealth mode) to retain my ASV. Looks stock but "seat of the pants" says OH YEAH.