3.0 Tdi Turbo Intake Pipe Mod - Audi A5 Forum & Audi S5 Forum
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post #1 of 26 Old 6th March 2017, 09:34 AM Thread Starter
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3.0 Tdi Turbo Intake Pipe Mod

Hi everyone, I have decided to improve my DIY airbox to turbo inlet pipe mod as I felt it could be made more efficient and also look a lot better.

I will increase the diameter and also the rigidity of the pipe by swapping the silicone bend in the system for a metal one as I have noticed the silicone pipe bending slightly under load. I will also smooth out the reducer part of the system for a more gradual reduction in diameter hopefully improving efficiency.

Firstly I got a pipe 76mm (3 inch diameter) with a 45' bend and a hole already cut to run a breather pipe.

The pipe is carbon effect (doesn't look too bad actually). 76mm (3 inch diameter)
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post #2 of 26 Old 6th March 2017, 09:35 AM Thread Starter
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Silicone reducer 83mm-76mm (from airbox lip to pipe)
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post #3 of 26 Old 6th March 2017, 09:36 AM Thread Starter
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Silicone reducer 76mm-70mm (from metal pipe to plastic turbo inlet pipe).
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post #4 of 26 Old 6th March 2017, 09:37 AM Thread Starter
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I then cut down the pipe with a hacksaw so it will fit perfectly in the silicone reducers before and after the bend. Best to sand the newly cut edges with fine sandpaper and then wash thoroughly as there will be some debris about that you don't want in the system. The pipe is just a cheap generic one from ebay, the reducers are 83mm-76mm and 76mm-70mm respectively. They are of a fairly decent quality. I threw away the reducer that came with the pipe as it was not up to standard.
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post #5 of 26 Old 6th March 2017, 09:37 AM Thread Starter
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Then assembled the intake but left the clamps loose so some jiggery can take place to get the intake to fit. It's a good idea to leave some wiggle room on all of the silicone reducers as its unlikely you will cut it to exact dimensions first time. So keep trimming a little off them at a time rather than trying to make it fit perfectly at the first attempt. It's easy to take more off, not so much to add silicone!


Attach the clamps at every connecting point and you should end up with something like this.
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post #6 of 26 Old 6th March 2017, 09:38 AM Thread Starter
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The plastic turbo intake pipe (just before turbo) is just from an A4 3.0tdi as the original pipe is actually of a wider diameter than the A5. So cut that to length to attach to the second silicone reducer. You can also use the stock A5 one but its slightly thinner at this point, hence why I opted for the A4 version. I found one on ebay second hand for a tenner.

Then time to install it. A fair amount of wiggling about and trial and error here but a combination of twisting and patience should yield a result something like this.
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Last edited by chrisrs180; 6th March 2017 at 09:41 AM.
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post #7 of 26 Old 6th March 2017, 09:39 AM Thread Starter
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Tighten up all the clamps to a reasonable torque, but careful not to over-tighten and split any hoses.

The blue hose came with the pipe from ebay and I have used an adapter to plump it into the crankcase breather pipe and put a zip-tie on it. Works perfectly and doesn't look too bad either.

Here's what it looks like with the engine cover back on.
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Last edited by chrisrs180; 6th March 2017 at 09:42 AM.
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post #8 of 26 Old 6th March 2017, 09:40 AM Thread Starter
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I'm happy with how it looks and it has further improved the throttle response. I will get it dyno'd soon when I can afford to but unfortunately I won't have any before and after results so you'll have to take my word for it that it is an improvement! Perhaps not in any power figures but like I say the throttle response is better.

Not too bad for 30.

Cheers.
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post #9 of 26 Old 7th March 2017, 12:20 AM
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Does look a lot better.

I'd be interested to see for myself the type of benefits this gives! I might look into asking a friend who is a welder/fabricator to make me a metal one.

Off the top of my head I'm pretty sure my intake has some sort of sensor where the elbow is on yours, I'm guessing this isn't part of the intake system and its just there to be attached to something?

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post #10 of 26 Old 7th March 2017, 12:40 AM Thread Starter
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Indeed it's the DPF particle pressure sensor I believe. I've just zip-tied mine to a non temperature affected pipe nearby. Was thinking of attaching the original securing from the intake pipe but need to think about how to make it look decent. Something to ponder at lunchtime anyway...
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post #11 of 26 Old 7th March 2017, 05:16 AM
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Do you think that you will get more power with this mod Chris??????


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post #12 of 26 Old 7th March 2017, 06:29 AM Thread Starter
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Unlikely to see much increase in power as the turbo already sucks as much air as it needs but making more air available to it without it having to work as hard should result in sharper throttle response. Basically making the system more efficient. May also increase mpg. Lots of small mods like this should add up to a decent increase and will complement bigger mods eg intercooler, larger turbo etc.

Last edited by chrisrs180; 7th March 2017 at 06:35 AM.
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post #13 of 26 Old 8th March 2017, 12:31 AM
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Originally Posted by chrisrs180 View Post
Indeed it's the DPF particle pressure sensor I believe. I've just zip-tied mine to a non temperature affected pipe nearby. Was thinking of attaching the original securing from the intake pipe but need to think about how to make it look decent. Something to ponder at lunchtime anyway...
oh okay I thought it was something important

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post #14 of 26 Old 8th March 2017, 02:20 AM
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Originally Posted by chrisrs180 View Post
Unlikely to see much increase in power as the turbo already sucks as much air as it needs but making more air available to it without it having to work as hard should result in sharper throttle response. Basically making the system more efficient. May also increase mpg. Lots of small mods like this should add up to a decent increase and will complement bigger mods eg intercooler, larger turbo etc.
Ok goddit thanks....


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post #15 of 26 Old 19th March 2017, 03:53 PM
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Not bad for the price !!!!
I bought a pipe form Darkside for 65, straight swap, done the cable tie thing with the sensor, also removed the little plastic flap from the bottom of the airbox housing and cut the bend off the plastic inlet pipe that feeds air to the filter, car seems more responsive and sounds more throaty !!!
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post #16 of 26 Old 20th March 2017, 10:12 AM
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Originally Posted by Scotsman0074 View Post
Not bad for the price !!!!
I bought a pipe form Darkside for 65, straight swap, done the cable tie thing with the sensor, also removed the little plastic flap from the bottom of the airbox housing and cut the bend off the plastic inlet pipe that feeds air to the filter, car seems more responsive and sounds more throaty !!!
How do you get that flap out? I tried for ages but it's stuck fast. Also what cable tie thing, I think I missed it

Beep beep.
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post #17 of 26 Old 23rd March 2017, 02:04 AM
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How do you get that flap out? I tried for ages but it's stuck fast. Also what cable tie thing, I think I missed it
I couldn't get it out either and after scratching my head for a while I just ended up mangling it out.
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post #18 of 26 Old 23rd March 2017, 03:05 AM Thread Starter
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This is from "Karls build thread" over at Audi-Sport website, details and shows where the butterfly flap is. (apologies if images don't appear I'm copy/paste from my phone.

I think the "zip-tie" being referred to is just to keep the DPF pressure sensor from moving about as when you remove/swap the inlet pipe you will take away its anchor bracket which it is attached to.

Hope this helps.

http://www.audi-sport.net/xf/threads....204785/page-3


Karls 3.0 TDI build thread | Page 3 | Audi-Sport.net
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Made another mod to the car a few weeks ago. Seems to improve the low speed pick up and logging airflow before and after there is a definate increase in airflow as the turbo comes on boost.
I do loads of data logging runs and comparing back to back two runs with one small change there is upto 10% extra airflow from around 1700 RPM upto 2500 RPM this then tapers off down to 3300 RPM.
The air box has a vacuum operated butterfly flap in the bottom that opens at some point, not sure when.
I took the butterfly out and added an intake trumpet that is used on the S4 / s5 cars.

[IMG]

The trumpet as it comes from Audi,

[IMG]
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post #19 of 26 Old 23rd March 2017, 03:07 AM Thread Starter
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Regarding the butterfly flap you put your hand through from the airbox/filter side and unhook it with a small amount of force. You should be able to feel it unhook from its hinges. If you physically open it with your hand from inside it should come free.
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post #20 of 26 Old 29th March 2017, 01:43 AM
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Do I take it that this mod can only be done after having the DPF deleted as removing the sensor form it's housing and just cable tying it out of the way?
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post #21 of 26 Old 29th March 2017, 06:28 AM Thread Starter
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This can be done to cars with or without dpf as in most cases the sensor will still be connected to downpipe/gutted dpf. (if removal has been done the most common way, leaving the sensor in to avoid it throwing fault codes) Essentially just relocating the sensor from old intake pipe to somewhere else in the engine bay. If your car still has dpf on this won't affect readings to ecu.
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post #22 of 26 Old 29th March 2017, 06:46 AM Thread Starter
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Sorry just to be clear the actual probe will still be on the downpipe/gutted dpf, the sensor (previously attached to a moulded plastic hanger on the intake pipe) can then be tied/secured somewhere else.
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post #23 of 26 Old 30th March 2017, 04:45 AM
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Great thanks for clearing that up, I know what i'm doing this weekend now
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post #24 of 26 Old 6th April 2017, 09:49 PM
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Quote:
Originally Posted by Scotsman0074 View Post
Not bad for the price !!!!
I bought a pipe form Darkside for 65, straight swap, done the cable tie thing with the sensor, also removed the little plastic flap from the bottom of the airbox housing and cut the bend off the plastic inlet pipe that feeds air to the filter, car seems more responsive and sounds more throaty !!!
what pipe are you refering to here? can you provide a link?

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post #25 of 26 Old 7th April 2017, 12:29 AM Thread Starter
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I reckon he means this one mate,

http://www.darksidedevelopments.co.u...cone-hose.html
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post #26 of 26 Old 9th April 2017, 04:11 AM
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Hi, sorry for not getting back to you sooner, i work away from home,here is the link.

2.7 / 3.0 TDi Audi B8 Platform Airbox to TIP Silicone Hose
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