Fixes for TD intake manifold

[tylernt]

I'm disassembling a junkyard 1.6TD and cylinders #1 and #4 look pretty good, but #2 had a stuck top ring and #3 had both compressions rings stuck. #2 also had a nice yellow spot on the upper conrod bearing where the top layer had been worn right off. #3 wrist pin came out easily by pushing lightly with my thumb, too.

I know that some folks have welded custom intake manifolds to balance the pressure to the four cylinders, since the stock manifold seems to give all the boost to the middle two cylinders, causing uneven wear as I observed. However I'm not made of money and wonder what ...less expensive... alternatives there were? Such as adding a small plate or baffle to the intake manifold above the #2 and #3 runners so the turbo isn't blowing air straight down them? I guess you'd really need a flowbench for experimenting.

I've never seen a TDI intake manifold, would that be a bolt-on an upgrade?

[aidan]

Tdi has different shaped ports, you could use a golf gti manifold, if its like here in the uk, the mk1 has the inlet to your passenger side, the mk2 has the inlet to your drivers side.
Edit - there'd be a bit of blocking off to do, such as injector holes etc

[jimfoo]

Of course if everything is apart, maybe you could do some grinding and match ports. Here is Deepmud's pic of his TDI which shows the manifold fairly well.

[tylernt]

Oh wow the TDI setup is totally different.

A gasser intake would be easy to find, but wouldn't it hit the turbo?

[aidan]

Does your turbo sit like on that tdi or behind the inlet? I have a tdi now and I can't remember what its like on a 1.6.

I'm looking for an sdi manifold for mine, it seems the non-turbo manifolds are better designed really for equal flow.
What is the 1.6 non-turbo manifold like?

[tylernt]

The IDI clocks the turbo 180* so it sits on top of the exhaust manifold. That leaves precious little room for the intake manifold, sandwiched between the head and the turbo like that.

The 1.6 N/A intake manifold has excellently balanced runners (even has a little plate/baffle to partially obscure the middle two ports) but doesn't have a round inlet -- it has a big rectangular opening to accept the air cleaner. It does have a round intake snorkel but it's plastic and not sealed to hold boost. If you could create a metal lid to replace the plastic, it would probably work.

The gasser intake is the best idea I've heard so far, but would probably only work with TDI exhaust manifold to clock the turbo down and out of the way.

[Black Smokin' Diesel]

The 1.6 N/A intake manifold has excellently balanced runners (even has a little plate/baffle to partially obscure the middle two ports) but doesn't have a round inlet -- it has a big rectangular opening to accept the air cleaner. It does have a round intake snorkel but it's plastic and not sealed to hold boost. If you could create a metal lid to replace the plastic, it would probably work.

I thought about that a while ago. The NA runners are pretty long and of constant diameter. You could remove the plastic air filter box and use an aluminum plenum of the same size and bolt/weld it to the runners You'd have one hell of a good intake manifold. You still need to flip the exhaust manifold and clock the turbo. Maybe it would be a good time to fab a custom equal-lenght pulse firing exhaust manifold. Not that the stock turbo manifold sucks, IMO it's pretty good for a stock part.

[aidan]

My main reason for wanting an SDI manifold is that there seems to be reports that if I had, for example, 130bhp with a bit of smoke, then after fitting the (clean inside) sdi manifold, cutting out the cat and blocking off the EGR completely, i'd have 130bhp with almost no smoke.

Does anyone have a photo of a 1.6D manifold?

[BellCityDubber]

My main reason for wanting an SDI manifold is that there seems to be reports that if I had, for example, 130bhp with a bit of smoke, then after fitting the (clean inside) sdi manifold, cutting out the cat and blocking off the EGR completely, i'd have 130bhp with almost no smoke.

Does anyone have a photo of a 1.6D manifold?

AFAIK (and I dont know much)


the 1.6d manifold has the filter right on the front of it so it would be hard to enclose and pipe the turbo outlet to it.

Correct?

[burn_your_money]

AFAIK (and I dont know much)


the 1.6d manifold has the filter right on the front of it so it would be hard to enclose and pipe the turbo outlet to it.

Correct?

You are correct, but you could just delete the filter and run it in the stock location on the TD.

[RabbitJockey]

yeah if you were running boost and a modefied 1.6d intake, you definetly wouldn't want the filter there, since you'd have one before the turbo anyway, i like the idea of a modded 1.6 na manifold as it does have nice flow

[jtanguay]

or... if you're looking for a flowed intake, check out dave at passenger performance.

he's has a really nice manifold for $450 (ceramic coated!!!)