Revo Intake For VW MK5/6 Golf GTI/R - FSI

Revo Open Cone Systems completely replace the OEM air intake for those who like to announce their vehicle is far from standard. Along with an aggressive intake sound, more air means access to more power throughout the rev-range

The factory 2.0 TFSI air-box works efficiently on a standard vehicle. As power is increased through tuning, however, it quickly becomes a major restriction, reducing the additional power offered. Ensuring the engine can get access to enough air is paramount when increasing power, an open cone air-intake system is the most effective way of achieving this, but not all products are made equal.

Having worked with a number of intake solutions during software development, we noticed a lack of high quality and more importantly, high flowing kits available. Working alongside some of the biggest names in the air filter industry, we engineered and designed what is still one of the highest flowing kits available.

The pioneering design allows air to reach the turbo as quickly as possible whilst minimising turbulence and restriction. As a result, boost can be maintained for longer, giving you access to more power throughout the rev-range along with a more aggressive sound, and performance you can feel all the way to the redline.

INTAKE PIPE

The Revo engineering team knew that to create the most effective kit, every component had to be considered to maximise and smooth airspeed. The system is designed around a lightweight 90mm intake pipe, mandrel-bent to maintain the internal diameter in the corners and to create a one-piece solution. This offers superior flow and avoids the air turbulence and resistance experienced on intake kits with multiple sections, usually caused at each join resulting in very turbulent airflow, ultimately restricting performance.

MAF SCALING

Ensuring correct MAF (Mass Air Flow) sensor scaling is the real art when it comes to designing air intake systems if incorrect the intake system can actually reduce power and cause major fuelling issues. The Revo kit integrates the stock MAF sensor in a specifically designed housing on the one-piece pipe to ensure correct scaling during fitment.

THREE LAYER FOAM FILTER

An intake system is only as good as the filter. This kit comes complete with a tried and tested Revo three-layer foam filter with an impressive 857cm² surface area, supported by galvanised, epoxy-coated mesh to ensure the filter cannot collapse. The filter has a large 180mm external diameter body and a smooth radius aluminium bell mouth, specifically designed for optimum airflow from the filter to pipe-work. Revo three-stage foam filters work very differently to conventional paper or cotton-gauze, which are surface filters designed to trap particles on the outer layer, instantly causing restriction.

AIR FILTRATION

Revo foam filters work by trapping dirt particles within each of the oiled foam layers, allowing air to negotiate its way through the filter, reducing restriction and offering much longer service intervals. We tested the filter at a leading motor testing centre ‘Mira’ on industry recognised dust load test. On a full dust load test, the foam filter was found to still be 99.1% efficient, filtering down to 5 microns while offering the least amount of restriction over similar products.

Heatshield

The intake system features a laser-cut aluminium heat shield that ensures the filter is well insulated from ambient under-bonnet temperatures. The shielding is designed to utilise the ducting in the factory grill to maximise airflow and prevent heat-soak.

SILICONE HOSES

The silicone hoses included in the kit are manufactured using high-quality automotive-grade silicone, engineered to combine the system using stepped necks to offer a smooth transition of air to avoid turbulence. The turbo inlet hose has also been specifically designed to fit both K03 and K04 turbo powered cars.

Research and Development

All Revo products are designed in-house and are rigorously tested utilising an in-house 3D printer, latest CAD and CFD programs, hub dyno and Revo data acquisition software. The Revo intake allows the turbo to run more efficiently, intake a larger volume of air and minimise turbulence to increase both power and torque, as highlighted during controlled dyno testing.

The Revo 2.0TFSI open cone air intake system was tested in-house to compare the performance against that of the OEM intake. First tested on a vehicle running the OEM intake with Revo Stage 1 software (K03), the Revo intake was then installed and tested in the same controlled environment to highlight the benefits.

Performance Data

The results show improvement throughout the whole rev range, but especially towards the top end of the rev range. Increased airflow delivers impressive peak performance gains of +16BHP and +5NM over the stock intake system on a K03 Stage 1 car. And +40bhp and +15NM on a K04 Stage 2+ vehicle compared to the stock OEM system.

Airflow

More air, less restriction. The Revo system was tested on a flow bench to highlight the efficiency of the kit in allowing more air to reach the turbo, quickly and with less restriction. The OEM system reached its maximum potential of 400 cubic feet per minute, compared to the Revo system which was able to flow 500 CFM with less restriction. This difference allows the engine to still make power at the top of the rev limit, whilst also highlighting the efficiency and less restriction at the lower end, resulting in smoother and increased throttle response.

Features:

• Increased Performance & Air Flow Efficiency
• Three Stage Foam Filter
• SCaled MAF Housing
• Single Pipe Design