The 2.0T FSI/TSI engine has the potential for substantial power. Despite its small displacement, the power ceiling is fairly high for even simple bolt-ons. An intake, turbo-back exhaust, coil packs, software upgrade, and a K04 turbo make the 2.0T an absolute weapon. However, in the process, weak points that would otherwise not be an issue present themselves. The Achilles heel of this platform is the intake manifold, especially with big turbo conversions. Thankfully, we have a solution for that. Fresh off the drafting tables and onto your engine, ready to help make everything safe and powerful, is our new FSI/TSI Fabricated Aluminum Intake Manifold.

With the factory intake manifold, you find that it becomes a serious weak point once you begin to modify the engine for more power. Besides the known issue with the intake runner flap failures, the original 2.0T intake manifold does not supply enough airflow to the engine for high-horsepower applications nor does it supply the air it can flow with proper consistency. We measured up to 10% differences in airflow to each cylinder from the factory manifold, which can result in dangerous conditions for modified engines. Naturally, we had to set out and make a solution that works with modern performance upgrades.

That variance of airflow is probably the biggest issue, as air/fuel ratio consistency across all four cylinders is paramount for engine health and longevity. When you run into that much variance, especially in modified applications, you are simply asking for something to break in a significant way. Our first challenge was to reduce that variance to a safe level, which we successfully accomplished in our final design. 

Not only is our intake manifold 53% larger in plenum volume than the original manifold, but it reduces the variation between air supply to each of the four cylinders down to less than 1%. On the flow bench, we recorded up to 8% CFM increase in airflow, which is delivered consistently to each cylinder. That makes our manifold already a massive improvement, especially for builds that use a K04 or larger turbo.

This volume increase is substantial for two reasons. Primarily, more air is needed to introduce more fuel and maintain proper air/fuel ratios. When hunting big power, that’s your base formula: supply more air and more fuel for more power. Secondarily, that airflow needs to be supplied in a smooth, consistent, and unrestricted way. That’s why we chose to go with a fabricated aluminum design over a cast manifold.

Our new intake manifold is fabricated sheet aluminum for smooth air passage that is uninterrupted by casting marks or imperfections in the plenum from traditional manufacturing, either in plastic or metal. We optimized the flow path of air for the smoothest transitions into the velocity stacks in the plenum for the most perfect air delivery solution available. With less turbulence, more air, and nearly identical delivery to each cylinder, your engine will produce more power with greater consistency without risking your engine’s health, even with highly modified applications.

Yes, if you are searching for a solution that eliminates all the problems that present themselves as you increase the power from your 2.0T FSI/TSI engine, then our brand-new in-house developed Fabricated Aluminum Intake Manifold is what you need. Available with or without full accessory kits or even as a fully customizable upgrade package, this manifold is designed to be a modular package that can help you take the next steps on your journey to high performance at your pace. Whether you just need the manifold and installation kit, or you need to upgrade your throttle body, intake, include an air/oil separator, fuel injectors, and more, we have a kit ready for you to make that jump and not look back. Build your 2.0T safely thanks to our newest additions from your friends here at ECS Tuning.

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