IE 2.5L 5 Cylinder Engine Dyno Project - Part Dos.

 

For the last few months, we've been working on various products for the VW / Audi 2.5L. After successfully installing it on our engine dyno, and getting the bone stock engine running on a Vi-Pec V88 ECU, we were able to start development work. If you missed the first blog post, check it out here: IE 2.5L Dyno Installation Part 1

Here's a quick video of the first few pulls- bone stock.

Since then, we've been working steadily on developing parts. Principally, our engineering staff has been working on a short runner intake manifold. So far, with just the addition of the manifold, we have been able to bump power output by about 40 horsepower- however development work continues. First we look at the valve sizes, cam lift curves, and other engine characteristics, and determine a baseline runner size and length. Then a manifold is carefully computer designed around these characteristics, and flow optimized using CFD.

IE Prototype 2.5L Intake Manifold

IE

IE Prototype 2.5L Intake Manifold - Cutaway View

IE

CFD

However, this is basically just a rough draft... It's not too carefully detailed, as many changes are expected during the development phase. This model is taken and chopped into parts which make it modular. This allows us to create new prototype sections and test changes to the plenum, lowers, or runners, without creating entirely new prototypes every time. We call these development mules...

IE

Next, our engineers use our Stratasys 3d printer to create functional, full scale prototypes out of ABS plastic... Through experience, we have determined the proper process to successfully run these parts directly on the engine. This gives us engine dyno power and flow results long before any designs are committed. Many companies would outsource this work and print only one manifold prototype to check fitment. In contrast, we typically will test as many as 20 refinements to a manifold design- everything from runner length, shape, size, and injector placement is checked... Below are some prototype parts from the development process of this 2.5L VW Part... Check them out!

Rapid

IE Prototype Intake Manifold for VW 2.5L

IE

Here are some of the sections by themselves... You can see this particular one features a large diameter velocity stack with a very generous corner radius. Below it is a runner section- notice the injector placement is different- one is stock, the other one moved upstream somewhat. These sections are printed layer by layer out of actual ABS plastic... We have even used them on boosted engines before.

Integrated Engineering Rapid Prototyped Inlet Bellmouths

Integrated

Rapid prototype of VW 2.5L lower intake manifold section

Rapid

With the parts ready to go and assembled, dyno testing is the next main stage. We have been testing different configurations and designs for this manifold for several months now, and are getting close to finalized results. By using a programmable aftermarket ecu, we can ensure that the test conditions are fair for each run. Our dyno controls and measures dozens of data channels as well, including airflow, EGT, air/fuel ratio, oil and water temps, fuel flows, and much more. This gives our engineers the data required to determine how to proceed next!

Engine Dyno Test Cell Control Center

Engine

Eventually, all of this will be combined into a finalized version of the manifold, and made ready for production. That version will be fully detailed out and optimized. A final complete manifold will be printed to check fitment on the car and confirm final power numbers before it goes to casting. Make sure to bookmark our blog for future updates as progress continues towards the final goal- tearing up the streets with a beautiful, American designed, engineered AND manufactured manifold!

43 thoughts on “IE 2.5L 5 Cylinder Engine Dyno Project - Part Dos. ”

  • Hi i'm a owner of a jetta 2009 w/ 2.5 engine, that same engine show below, and I want know if you sells thats manifold.
    I need this!!


    Thanks a lot

    Reply
    • Fred,

      The manifold is under development currently. ETA: Fall / Winter 2012. It takes a lot of work to develop parts to this level, and that means time :)

      Reply
      • Pete,

        After reading this post I had a few questions. Since I am running Ferrea +1mm Intake and Exhaust valves will there be any drawbacks to your intake manifold design for my application?

        To further clairify you're tuning for what I assume is OEM - CAM, Valves, pistons etc. While the motor I've had built contains virtually every part you stock for the 2.5L motor.

        Thanks,

        -Hans

        Reply
        • Hans,

          That won't be an issue at all. Cams will change things, but we aren't that far along just yet... I also have it tuned at the moment for about as high of a powerband as I think most would want for a street car- so even with cams I think we will be in good shape, with the exception of huge race cams.

          Cheers,

          Pete

          Reply
  • Please god give us a release date.......I can't take it any longer!

    Reply
  • Can I be a test mule for this please?

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  • Hope the price is a bit more reasonable than united motorsports Sri or c2's. Though I hear theyre good products no doubt about it, just that 1000$ range kills sum of us..

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  • Yes, please price your at a better point than the others. $1k is way too much for this item. $699.99 is at the top of what they should be.

    If you do this, you will shut down everyone else and be the go to for SRIs. And you will still make plenty of scratch.

    Everyone is waiting for a reasonably priced SRI.

    Reply
    • Agree with the post ^

      Reply
    • $699 would be great but not realistic. Keep in mind IE has to price it accordingly also to leave profit margin for them and their dealers. Which means that this manifold would have to cost them about $400 which im sure isnt the case.

      Also dont forget how limited the 2.5 market is. The 1.8T sri is $800 so at best this one will probably be the same price.

      Reply
  • hey guys i'm loving the process. i know for myself being stage 2 turbo i really like the idea of having a CAST manifold. can you speak of the benefits of going with a cast manifold over a tig welded sheet built mani? overall to me i like the look of a nice cast unit and can't wait to see what price point you guys come to the market with. i'm sure you'll sell more if its "fair" i surely trust your knowledge with the 2.5 and look forward to ordering MANY parts very soon (internals?)

    Reply
  • Cant wait!!!!! Hoping this product will work with an APR tune since thats what my local shop uses.

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  • Hey guys looks great I am storing my pennies to get one of the 5cyl SRi's. one question: will this require a BS CPU flash for an extra 150$ or will this be primarily bolt on and go?

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  • I am really interested in this product. Is there an updated eta when this will be available. Also, would you be be to give us an idea of about how much this will cost?

    Reply
    • We are still in testing and development, at this time we do not have an appropriate ETA or a estimate on cost. Keep tuned for more info in the future.

      Reply
      • Is this going to be only for the old 2.5 motor or the newer one? I believe the newer one has something to the left of the engine that blocks space that the older motor had available.

        Reply
        • Aaron, as of right now these will not work on 2.5L engines with hydraulic power steering pumps. It will work with all 2.5L engines with magnetic power steering. We may be able to offer a kit to re-locate the power steering pumps on those vehicles at some point in the future, depending on how cost effective it might be.

          Reply
  • Any updates on 2.5 intake?Iam so excited to see you guys doing R&D on this motor.I think its the most underated motor ever i mean the head on this engine really flows.And come on look at those honda motors why do they even bother!300hp an 150ftlbs of torque lol at 15psi they make no torque.The 2 5 makes alot of torque love this motor way underated motor.But you guys are gonna change that lol

    Reply
  • scott youngblood December 22, 2012 at 8:51 pm

    When is the intake be ready?

    Reply
  • Just wondering what sort of time frame we should expect for this release? I have been waiting for the ultimate sri that was tuned and tested and truly cannot wait for this manifold... You can email me a response if need be, thanks for the great products too!

    Reply
    • FInal design work is finished, manufacturing is beginning soon. This is a lengthy process so keep your eyes open for more updates soon.

      Reply
  • Will the manifold mesh with the APR Intake? Also is there any insight on moving ps pump or changing it? Any info would be great as I will be getting my car prepped soon. MKVI Jetta SE. Granted these will be the highest sold Jettas of all time in the North American market it makes good bussines sense to make this work.

    Reply
    • We are not designing it to work with specific aftermarket intakes, I can not say if it will or will not work with any specific brand of aftermarket intakes, we are not testing it for so either. We are however, planning on releasing our own intake design to work with the manifold that will be available with the manifold upon release and software as well. No news on the PS pump for MKVI Jettas. It is something we are still looking into, but our focus right now is getting the manifold manufactured and released for all the engines it will fit without any major modifications. Keep your eyes open for more information on the PS pump issue as it becomes available, we wil keep you updated.

      Reply
  • OK guys we get that you cant give specifics on time or price , but how about some eye candy.....some official pics or something. Also, will it be necessary to buy software specific to the SRI or will it be bolt on and go. I am out of my skin in anticipation for this product !! cant wait.

    Reply
    • The price will be in the range of $850-$925 depending on options. The only options really on this manifold will be the finish choice (raw aluminum or black powder coat). You will definitely want to upgrade your software at the same time as the manifold.

      Reply
  • Im sure specs wont be out till the product is available for sale. But I was just wondering if there any improvements on MPG since the SRI will be improving the engines efficiency.

    Reply
  • scott youngblood January 29, 2013 at 5:38 pm

    Come on guys tell us something we havent heard anything in months.You guys didnt give up did you lol?I know this takes time but any kind of update would be great you got people going fking nuts here i mean come on.Have a soul people.thanks

    Reply
    • Expect to see a pre-sale around the time of Wuste car show (end of may). We'll have an updated release date when we launch the pre-sale. Hang in there!

      Reply
  • Gabriel from quebec March 13, 2013 at 9:18 am

    i cant wait for the release !!! Where can i find more news about it !! give us a release date :)

    Great job by the way

    Reply
    • Expect to see a pre-sale around the time of Wuste car show (end of may). We'll have an updated release date when we launch the pre-sale.

      Reply
  • Just wanting to know status on this intake manifold? I and many others are waiting for this intake manifold. I am also not putting my Turbo setup until. I have the intake manifold in hand. Let me know if u need a test car. I will be happy to pay to be a test car.

    Reply
    • Expect to see a pre-sale around the time of Wuste car show (end of may). We'll have an updated release date when we launch the pre-sale. It will be worth the wait, so hang in there.

      Reply
  • any update on when the intake manifold will be available and what the price will be?

    Reply
    • The price will be in the range of $850-$925 depending on options. The only options really on this manifold will be the finish choice (raw aluminum or black powder coat).

      Reply
  • michael Wise May 5, 2013 at 4:20 am

    I am just waiting to have some updates on this intake manifold. I am waiting for the intake so I can run boosted. Please give us many beggars a update or a release date. I need something a little more concrete but I am in just in a pickle cause I have had a vacuum leak with the old plastic manifold where the boost cap is for quite sometime. I haven't wanted to replace it with C2 intake manifold, cause IE said there intake would be out soon. So this is why I would like an update.

    Reply
  • Sounds like you guys were able to cut costs without cutting corners. Impressive! I may invest in one of these well developed IM for my 2.5. Would there be a possibility for other color options for the manifold?
    I know a car community that would love to see products from Integrated Engineering. The only IM for them is a Cosworth piece.

    Reply
    • Integrated Engineering June 5, 2013 at 11:04 am

      Thanks Jeff,
      The manifolds will be available in raw casting or in a black powder coat finish. If you would like a different color the raw casting will powder coat very easily, a local coater to you should be able to handle the job easily. Thanks for the kind words!

      -IE

      Reply
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