High Flow K04 Mani vs Ported OEM Mani Comparison

Ported OEM Manifold, less, same or more?

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Welly

Welly

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A lot of interest in the higher flowing manifolds for the K04 at the moment...

As many of you will know already, I have an 034 motorsport non ceramic high flow K04 manifold fitted to my S3 at the moment.

Sadly, this has met with an untimely demise.... after only 1000 miles. That, however is a conversation for another day.

My question is, and I am sure many of you ask the same, how much better than OEM are these manifolds?

And thus, I propose to answer this question.

I have dyno prints from the engine at it's peak performance when using the 034 manifold. I will now be fitting a ported (by Badger5) OEM manifold to replace it.

Pics of the work I have no doubt will feature, but it will be interesting to see the performance difference...
 
Last edited by a moderator:
Sorry, just noticed my spelling mistake on Poll option 2.... Mods, would one of you please adjust as I can't seem to.

Should say: 'Ported OEM will make the same power'

:salute:
 
Im all in favour of porting but as u know its a plus minus effect all the time , do you have links to the manifold in question welly ?
 
Option 4

Get a TSR one

To make the most of any porting work it has to be ported the full length or the runner and even more so on a K04 manifold, just a bit hard to do on are manifolds.

The TSR one is the same diameter though out and has a much better collector to the turbo
 
the runners themselves are not too bad.... relative to the collector which is a jumble of combining gases squeazing their way out of the manifold.. Deffo some reduction in backpressure at high flow possible in this area.

we will see.

TSR one is nice, and is a lot of labour to make hence not cheap.. Its oversize pipes for k04 install tho, so i cant see it restricting anything, but it still has to flow that past the small in comparison k04 hotside.
 
The same, based on the graphs thus far.

I take it we're taking the manifold as the only variable, and the rest constant? i.e. Bill's 3" TIP etc?
 
OK, the change has been made, and the manifold swapped over.

As I have said in the other thread results look promising.

Turbo is faster to spool, and airflow at the top end of the revs is the same, if not slightly more than the 034 High Flow manifold.

Logs to follow, however, dyno results will be available on Sunday night.... hopefully.
 
OK, logs as promised.

Ambient temp outside tonight is 8.0 degrees Celsius.

Results - surprising... Displayed below are Blocks 002 and 020.

Logs with 034 Manifold fitted:

Code: 
	Group A:	'002				Group C:	'020			
		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization
	TIME					TIME				
Marker	STAMP	 /min	%	 ms	 g/s	STAMP	 CF	 CF	 CF	 CF
	147.11	840	23.3	2.05	4.06	146.71	0	0	0	0
	148.3	1240	45.9	3.69	10.92	147.9	0	0	0	0
	149.5	1440	52.6	3.69	13.25	149.09	0	0	0	0
	150.69	2360	77.4	5.74	36.08	150.3	0	0	0	0
	151.9	4040	177.4	10.66	153.31	151.5	0	0	0	0
	153.11	7480	187.2	15.17	264.14	152.71	0	0	0	0.8
	154.41	6040	191.7	17.63	254.06	153.93	0	0	0	2.3
	155.61	7400	188	15.17	265.83	155.21	0	0	0	2.3
	156.81	5520	191.7	18.45	245.67	156.41	0	0.8	0	2.3
	158.01	6280	191.7	18.04	258.81	157.61	3	0.8	0	1.5
	159.21	6840	191.7	16.81	264.14	158.81	3	0.8	0	0
	169.8	4480	3	0	2.97	170.59	0	0	0	0
	171.09	4160	6	0	5.64	172.1	0	0	0	0

With ported OEM manifold fitted:

Code: 
	Group A:	'002				Group C:	'020			
		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization
	TIME					TIME				
Marker	STAMP	 /min	%	 ms	 g/s	STAMP	 CF	 CF	 CF	 CF
	240.99	3520	125.6	9.02	93.69	241.38	0	0	0	0
	242.41	5440	191.7	18.45	244.83	242.89	3	0	0	3
	243.8	7120	191.7	15.99	267.53	244.28	2.3	0	0	3.8
	245.08	5480	191.7	18.45	249.42	245.48	0	2.3	0	3.8
	246.28	6240	191.7	18.04	258.81	246.68	0	1.5	0	3.8
	247.48	6840	191.7	16.81	267.53	247.88	0	0.8	0	3
	248.68	7320	190.2	15.58	266.39	249.1	0	0	0	1.5
	249.99	5840	191.7	18.04	251.94	250.49	0	1.5	0	3
	251.29	6200	191.7	18.04	255.36	251.69	0	0.8	0	3
	252.49	6520	191.7	17.63	258.58	252.98	0	0	0	1.5
	253.78	6840	191.7	16.81	264.14	254.28	0	0	0	0
	255.19	7120	191.7	15.99	264.69	255.59	0	0	0	0
	256.39	5640	3.8	1.23	0.19	256.77	0	0	0	0
	257.57	5400	3.8	0	4.69	257.97	0	0	0	0

Another section from the same log:

Code: 
	Group A:	'002				Group C:	'020			
		RPM	Load	Inj. On Time	Mass Flow		Idle Stabilization	Idle Stabilization	Idle Stabilization	Idle Stabilization
	TIME					TIME				
Marker	STAMP	 /min	%	 ms	 g/s	STAMP	 CF	 CF	 CF	 CF
	118.65	3920	55.6	3.69	62.17	117.84	0	0	0	0
	119.95	4800	191.7	17.63	213.28	119.15	0	0	0	0.8
	121.36	5840	191.7	18.04	254.92	120.46	3	0	0	0.8
	122.65	6560	191.7	17.63	260.25	121.85	3	0	0	0.8
	123.87	7080	191.7	15.99	268.08	123.05	2.3	0	0	0
	125.24	5720	191.7	19.27	265.94	124.35	2.3	0	0	0
	126.55	6120	191.7	18.04	256.64	125.64	0	2.3	0	3.8
	127.85	6480	191.7	17.63	261.44	127.05	0	2.3	0	3.8
	129.07	5040	1.5	0	0.22	128.25	0	0.8	0	3.8

As can be seen here, the OEM manifold is consistently flowing more air then the 034 manifold, with similar timing pull.

Discuss....
 
Welly said:
As can be seen here, the OEM manifold is consistently flowing more air then the 034 manifold, with similar timing pull.

Discuss....
Click to expand...

Erm... Ported OEM is better???? :w00t:



As long as it lasts (fingers crossed).
 
OK people - news.

And it's not good news. Long and short of it is that the logs were in fact the red herring.

Power has now dropped down to around the 300 BHP mark with the OEM manifold fitted. Disappointing to say the least.

We had to make several adjustments to the config of the map, including fuelling, which shows just how much this affects the engine.

Boost has also had to be dropped

It looks like the OEM manifold strangles the flow to the point that it just can't get the air out.

The torque is falling much faster than it did with the 034 on.

Everything does fire up around 800 RPM faster though, which is interesting, yet seems to be counter productive.

So, the facts are on the table people. The high flow manifolds do aid flow as thought before.

This seems to be more apparent on the large port heads ultimately. The smaller port engines don't seem to suffer so much from the smaller runner on the OEM manifold.

Anyway, regardless, I am 30 BHP down from the ported K04 manifold.

Conclusion - they do make a difference in peak power. Although I would say the it is more useable with the OEM manifold fitted due to the earlier spool.
 
oh no, can you live with 30 less bhps knowing that you have had more? Will you save up for the TSR item?
 
will u get a refund of the 034 mani as it cracked like crazy?

unlucky with the BHP dude and dont leave yaself in the **** for christmas mate! :)

good luck dude
 
DaveA3 said:
will u get a refund of the 034 mani as it cracked like crazy?

unlucky with the BHP dude and dont leave yaself in the **** for christmas mate! :)

good luck dude
Click to expand...

I'm always in the **** dude, it's just the depth that varies....

034 have sent a replacement allegedly.
 
have they recognised that replacing the manifold is more than just the cost of their manifold? i.e. labour, nuts and bolts ...
 
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