1.6 intake manifold?

[orangea2vr6]

turboing my 1.6 and i'm looking for info on what intake manifold to use I heard about the g60 one and possibly a 8valve one just need to know which one I should get thanks.

[RabbitJockey]

you can use either one, the important is the g60 boost return valve, and just use that and bolt it down to the intake manifold of your choice, just make sure the throttle body isn't there

[jeremp]

You can use a reg FI intake with an adapter like this one. http://picasaweb.google.com/jeremiahprickett/Intake/photo#5049323196219400146

[935racer]

Remember that if you use a gasser intake manifold you will need to flip the exhaust manifold and turbo upside down, which will than give you some clearance issues for making a downpipe because its so close to the transmission shift rods. Alternatively I just came up with these:

[boosted_diesel_84]

that manifold is awesome!!! how much?

[935racer]

$375 without ceramic coating, $475 as pictured with the ceramic coating (which I highly recommend).
Check this thread for more info:
http://vwdiesel.net/phpBB/viewtopic.php?t=7676

[boosted_diesel_84]

any flow and velocity numbers compared with a stocker?

[935racer]

Not yet, not sure what you mean by velocity, all we can measure is increase in mass flow (in CFM) and difference in CFM per port (balancing flow across the ports).

[boosted_diesel_84]

volocity= basically the air speed, for example, if the ports and runners are too large it will flow huge numbers, but volosity will be down, and it will have no power in low to mid rpm's, and may only run well at 12,000 rpm for example purpose only,i am NOT saying yours is this way, i just like to verify and have numbers, at the Audi/ VW shop i work at we can flow, at any depression and correct for different ones, measure volosity, swirl and tumble, also port map, and measure any given point in a port with a probe to find dead spots we are also sales reps and help line for Audie Technology, look it up sometime if you have never heard of it, but i just would like to know how much this will improve my TD before i drop even more into it, even though i probably will, thanks!

[935racer]

volocity= basically the air speed, for example, if the ports and runners are too large it will flow huge numbers, but volosity will be down, and it will have no power in low to mid rpm's, and may only run well at 12,000 rpm for example purpose only,i am NOT saying yours is this way, i just like to verify and have numbers, at the Audi/ VW shop i work at we can flow, at any depression and correct for different ones, measure volosity, swirl and tumble, also port map, and measure any given point in a port with a probe to find dead spots we are also sales reps and help line for Audie Technology, look it up sometime if you have never heard of it, but i just would like to know how much this will improve my TD before i drop even more into it, even though i probably will, thanks!

I understand velocity, but I am unsure how you are supposed to go about measuring it for this application, there are so many variables I don't know how you could measure it and be useful for the average guy. Balance of flow across the ports was the main thing I had in mind when designing this manifold with its dual plenums, there is a narrow slot that divides the two to help evenly distribute the air across the ports.

Now the ports are stock on this manifold, and while "runners" are not an ideal length for this engine it was the best I could do as far as space and money is concerned. Velocity doesn't really have anything to do with the rpm the manifold is most efficient at, that has to do with harmonic tuning.

How are you guys measuring swirl and tumble? Smoke?
What flow bench are you using?

[boosted_diesel_84]

the bench is a custom one built by my boss, its really neat, and super quiet, you can talk on the phone right next to it while its doing a flow test, all you do is bolt the head on it, click the green button and walk away, it does it all for you, even opens the valve, and does all the calculations, heres a pic of his bench, go here for other info http://www.audietech.com/

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[foxracer1]

Nice! I used the ones we had at UNOH they were loud! and you had to watch the manometers and then calculate it.

[saurkraut]

I guess I'm not getting the "low velocity = low power @ low RPM"  Is this a gas engine thing?  IE the mixture gets screwed up because there is not enough velocity to carry the fuel into the cylinder?

I don't know if this translates on a diesel.  The swirl and mixing happens in the swirl chamber (precumbustion camber).

We're not only interested in getting alot of air into the engine, but to make sure each cylinder gets essentially the same amount of air.

Diesels are butt backwards compaired to gassers when it comes to fuel:  More fuel in a gasser = cool  More fuel in a diesel = hot.

The injection pump essentially puts the same amount of fuel in every swirl chamber.  If the air volume in the cylinders is different, due to a crappy intake manifold, we're out in the long grass if we want to push the engine closer to the limits. IE the cylinder with more air will be cooler than the cylinder with less air, for the same injected fuel volume.

So if we're looking at a max EGT, we could be burning up one or two cylinders, while the others are doing just fine.