MKV intake modification (Modshack prototype)

[mikinoz]

Thanks to Ian from Rennenhaus for working with me to get something to work in the TDI engine bay.

What has resulted is that we are using a Modshack R32 intake as a filter prototype. There was a complete removal of the standard intake before the MAF - and now lives in the shed. The kit that comes with the R32 model filter required only limited adjustment (ie. bench grinding for the bracket and a branch to be tapped before the MAF for the vacuum line).

The bracket is joined at the Earth connection point so the paint on the bracket requires removal.

So down to the nitty gritty;

Deciding the best location for the filter;

http://gallery.mac.com/mikinoz/100074/photo1204972120176/web.jpg

http://gallery.mac.com/mikinoz/100074/photo1204972105219/web.jpg

After deciding that the best place for airflow was inline with the grille, the following is the result;

http://gallery.mac.com/mikinoz/100135/IMG_0369/web.jpg

Looking through the original air intake area;

http://gallery.mac.com/mikinoz/100135/IMG_0370/web.jpg

Looks very discreet;

http://gallery.mac.com/mikinoz/100135/IMG_0371/web.jpg

http://gallery.mac.com/mikinoz/100135/IMG_0372/web.jpg

Location of plumbing;

http://gallery.mac.com/mikinoz/100135/IMG_0374/web.jpg

Be aware - tight fit - potential rubbing;

http://gallery.mac.com/mikinoz/100135/IMG_0375/web.jpg

Location of the mounting bracket;

http://gallery.mac.com/mikinoz/100135/IMG_0377/web.jpg

http://gallery.mac.com/mikinoz/100135/IMG_0378/web.jpg

The 1000 kilometer review:

Noise: There is a lower tone and some intake drone - nothing like the slurp of a petrol - but notable.

There is slightly more noticeable blow off sound from the waste-gate.

On the highway and around town, not a problem with the noise.

Economy:

At this stage I think there is limited around town economy increase. On the highway, I think that it is saving around .4 - .7 liters per 100 km.

Performance:

Most noticeable is that how much smoother the car is at lower revs. The main problem I had before was the VERY large delay in the lower rev range. This area is smoother and more pleasant than the OEM system.

No great variance on the soot from the rear.

Overall:

I think that as part of the intake, this is a good addition. It will assist with induction of cooler air and more of it undoubtedly.

In a perfect world I would next approach the exhaust on this car, however I am not really willing to invest that amount of money yet.

I would give this solution a thumb up - and as there are not many others out there at this stage, serious consideration if I was contemplating other mods like Chip or Exhaust.

[Mischa]

cooool :cool: any reason you picked that particular one?

[Greg Roles]

Cool again, I was hoping you posted it in the diesel section.

[Jaymz]

The more i look at this the more it makes a lot of sense.:)

Tell us about the cost and also the filter. Is it paper, expected life, ease of replacement, places to get replacements and also cost.

Cheers,
Jamie

[Transporter]

Yeah,
and also, does it have the same filtering performance as OEM filter?
So, it doesn't shorten the engine's life.

[mikinoz]

This is still going strong.

It has been great, and have no complaints.

Service is due so I am going to take it off, and then head to the next dynno day stock - do a run - change over to modshack - and do another run for comparisons sake.

It is a K&N filter so I am of the opinion that it should be safe for the engine and the renewal process is pretty straight forward.

[Greg Roles]

Mate, having a few weeks of inlet research under my belt now, you certainly made a top choice. Phenominal product.

Did you notice on the Mod Shack site they mention the grid in front of the MAF is an 18% inlet restriction, and the greatest one to boot? It's there to smooth the airflow after the 90 degree stock lid top, and they mention it can be removed on fitment of their filter like you have done.

Certainly be in my plan in your shoes you lucky b@stard!

[mikinoz]

Can you link the reference to 18% reduction? I am unable to find it.

[Greg Roles]

No worries, the site does go on and on a bit:D

Under "Stage 1" link in the upper right of the homepage.

Half way down the page:




Thoughts on:

Panel filter Upgrade: The issue is NOT the Filter medium, but the airbox design itself. Air comes in through a small snorkle, changes direction 90 degrees, flows through the filter, and changes direction another 90 degrees before it heads off into the MAF. It's no wonder the MAF housing needs restrictive vanes and screens (18%) to smooth the airflow.




Then under the pricing:



TTDA general info:


On flow: In the stock airbox, air changes direction twice (90 degrees each time) to get to the MAF. Using the inverted cone filter, air enters the MAF smoothly. So smoothly in fact, that you can remove the plastic vanes and screens from the MAF housing which is the biggest restriction in the intake
system.


http://www.modshack.info/ttda.htm

[Logzy]

Looks great and i'm not at all being negative in the slightest, but isnt this basically a cone shaped pod filter (k&/n or similar) in a round tubular insulated housing.?

I love the fitment of it and the way it sits with the inlet aimed directly forwards, frankly you couldnt ask for a better setup .
Looks like I'll be building myself one to get rid of those two 90deg bends.

With such a simple design theres no reason why a home built unit wouldnt give the same results as this $250+ unit.

Im building myself one.;)

[Greg Roles]

You got it mate.

The filter is nothing major, easily obtained.

The beautiful phenolic tube and insulation he uses isn't so easy. I've tried to play with phenolic plastic before...good luck finding sheets let alone tubes of that size! It's one of the best insulators available.

THOSE things are the major things for me Log-man.

[vanDub]

It is a K&N filter so I am of the opinion that it should be safe for the engine.

Don't get me wrong, this looks like a great improvement over standard but I recall reading on one of the sites a while back that K&N Filters are known as "MAF Killers" due to the oil from the filter medium getting into/onto the MAF as screwing it.

Any views on K&N's as I intended to use one until I read about the "MAF Killer" bit. (can't find the link now of course)

[Logzy]

Don't get me wrong, this looks like a great improvement over standard but I recall reading on one of the sites a while back that K&N Filters are known as "MAF Killers" due to the oil from the filter medium getting into/onto the MAF as screwing it.

Any views on K&N's as I intended to use one until I read about the "MAF Killer" bit. (can't find the link now of course)

This is also a concern of mine too which i was thinking about last night.
Its also been proven that the standard air filter does a better job of filtering than what the K&N filters do.
So therefore they are not protecting your engine as well as the standard.

[mikinoz]

If there is proof that the standard filter is better at protecting the engine, and you are not concerned about the power loss from the standard airbox restrictions stick with it I say.

I have had no problems with K&N in the past (with various Subaru / VW / Holden) and feel that they are adequate.

Not living in a sandy or rural area also leads me to be less concerned.

As we are not planning on holding on to the car for longer than 3 or so years, and the fact we have only done 16K in 12 months - I am not sure that there is a lot of difference that will be made to engine life in my ownership.

[vanDub]

This BMW link gives some views on K&N Filters

http://member.rivernet.com.au/btaylor/BMWText/technical/K&NFilters.html

Seems K&N Filters, esp pod filters are worse than standard unless insulated from engine compartment hot air (which this mod seeems to do). At best they appear to be borderline for performance gain and allow more dust through. Better airflow new out of the box but loading up very quickly for WORSE airflow. Not good with K&N recommending cleaning only every 50K miles.

[orsegtsport]

I've run K&N filters on all my cars without issue. The guys at Tunit in the UK reckon that running a K&N panel filter on their remapped GT TDI has improved airflow by around 30%, and provided an appreciable performance improvement. I think the key to avoiding MAF sensor problems is simply not to over oil the filter.

[Greg Roles]

Ahh the old K&N debate....

I have a panel in my TDI, and whilst I ran the stock one on the dyno, when I swap it I don't really notice anything. I just like the fact that you CAN service it, and in that way pretty much keep it at optimum all the time. Again in both Modshacks and my humble opinion, the problem is the lid elbow, not the filter.

I too found a bit of info on the oil killing MAF's, but they were speaking around 50 to 80 thou MILES, and as a new MAF costs a whopping $60 US, it's no big deal really.

All the same it's WHY I have a nice Apexi dry pod on it's way, and it will go into a shielded pod setup like this. Mik's setup is great for heat shielding, certainly NOT an open pod style, and the only possible flaw I can see it that the front of the beautiful Modshack tube would ideally be sealed so that air can ONLY be drawn through the front entrance, and not around the front edges of the tube.

Mik's words sum it up...he FELT a difference. After all, isn't THAT the main goal?

[Dyldo]

howdy all. Figured i'd resurrect this thread with a few comments. I've recently taken my Modshack VTDA off my TDI after about 20K kms, and have also done about 2 full tanks of fuel after having it off.

I have clearly noticed a quieter engine (remember we like a little bit of intake nastiness, its why we go pod filters :)) but the lag and delay is back. There is also a distinct lack of low and mid pulling power because of the lag.

Lastly, I've noticed i am getting 100kms LESS out of each tank now, with absolutely similar driving to my previous 20K kms (mostly 160Kms per day of highway at least) so the economy has gotten worse. obviously, its still awesome dieselness compared to petrol though, but still.

Conclusion - The VTDA on the TDI was a great mod and helped fill a torque hole and increased fuel econ markedly.

[benough]

Who sells them? I assume they come with a pod filter in them?

[mikinoz]

Ian at Rennenhaus - you need the model to suit MKV R32.