A K04-064 turbo inlet. Designed to reduce the pressure drop at the turbo inlet. For K04-064 equipped 1.8T engines. This product is an STL file which will be sent with email after purchasing. Customer 3D prints the part.
Why Did We Design This?
We use a K04-064 equipped 1.8T 20V motor for product development. The turbo inlet routing is pretty tortuous. There is a 90 degree bend immediately before the compressor wheel (part of the turbo housing), there is another 45 degree bend around 5cm before that, which in turn comes from another 45 degree elbow, which then leads across the back of the engine to the MAF sensor and air filter.
In short the air has to do a 180 degree turn in a short distance while also being sucked into a smaller diameter pipe.
The original solution on this engine was to use a 45 degree reducer silicone hose which connected the metal turbo inlet neck to the main 80mm intake piping.
The Issue
This setup was unsatisfactory for a couple of reasons.
First, the 45 degree reducing silicone elbow mounted to the turbo, left a large lip inside the pipe (the lip being the metal elbow on the turbo itself). This lip was a huge 5mm around the circumference of the pipe. In short a massive turbulence creator causing a pressure drop at turbo compressor inlet.
Secondly, it was a reducing elbow. We are asking the air to turn 45 degrees, which in itself is less than ideal, but we are also asking the air to enter into a smaller diameter. Another impediment to flow.
This page contains flow animations cause by elbows in pipes. A 90 degree bend can cause a 43% reduction in flow.
MoviChip Turbo Inlet
This low loss 1.8T K04-064 turbo inlet goes between the turbo and the 45 degree bend on the main intake piping and is connected at both ends by a silicone joiner.
Benefits
1.This inlet gives a smooth transition between main intake pipe turbo inlet reducing pressure loss. The small end of the low loss elbow has the same internal diameter as the K04-064 inlet.
2.Flow improvement through elbow. This low loss turbo inlet contains a full length guide vane to minimise pressure loss. Guide vains in elbows can reduce pressure loss by 25%. Source. And flow resistance by 38%. Source.
In Summary
This low-loss inlet eliminates internal flow restriction caused by the lip (on turbo inlet). It also reduces pressure loss through the reducing 45 degree elbow phase (internal turning vane).
Results
This elbow has not been dyno tested. It has been tested extensively on road.
Impressions
Turbo appears to want to spool earlier and faster, perhaps by as much as 500 RPM in some conditions.
Intake noise seems to have increased markedly. Engine uses open paper filter mounted behind battery.
Maximum power increase not certain. In any case, not something that is noticeable from driver’s seat.
Generally the turbo seems more willing to produce boost and engine seems more responsive with less effort.
Not huge differences, but in our opinion, noticeable.
Conclusion
As I stated above, this low loss K04-064 turbo inlet has not been dyno tested but to our eyes the elimination of the issues with the original setup (45 degree reducing silicone elbow) are sound and at the least will have not made the engine perform worse.
NOTES – Before Ordering
Please look at the pictures carefully. The product is non-refundable for any reason.
Mounting Position
The K04-064 on this engine is mounted further back compared to upgrades which uses a simple spacer plate. This product may or may not be compatible with K04-064 upgrades which use a thin spacer plate.
Intake piping will need to be fabricated to match this elbow.
Dimensions
Large end size is 80mm outer diameter, 73mm inner diameter
Small end size is 53mm internal diameter, 63mm outer diameter. Same diameters as the metal elbow on the turbo.
Temperatures
We use this elbow with Nylon suited up to 170 Celsius, we have not seen any heat or erosion related issues. Be sure the material you choose for your 3D print is suitable.
