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Official Integrated Engineering MK6 2.0T Performance Products Thread

Tyler@IE

Ready to race!

In this thread we will go into detail on what we have to offer for your MK6 2.0T TSI, answer questions, offer technical advice, and give you insights to upcoming products. Please feel free to look around and ask us any questions that you may have.



Integrated Engineering started several years ago engineering and manufacturing high quality engine parts for VAG applications. Today thousands of customers are hitting the track, drag strip, and street with our engine parts. Our engine internals range from forged connecting rods and intake manifolds to valve train components. However, as the company has grown our product offering has also expanded greatly. Integrated Engineering, based out of Salt lake City, Utah, now operates out of a 20,000 square foot facility with resources including a full CNC machine shop, Superflow engine development test cell, Dynapack Chassis Dyno, 3D prototyping capabilities, and our in-house engineering team.

In the future you will see several complete performance packages coming to market that combine our well known hardware with IE stock ECU software. These will typically be in the form of our PowerPacks and turbo kits. In addition to complete packages we have also developed new products such as FDS Intercoolers, high pressure fuel pumps, and even chassis components. In our new product lines you can expect to see the same level of attention to detail and quality as many have you have come to expect from our engine parts.


IE offers a broad range of performance solutions to reach your power goals with ultimate quality and reliability. From simple bolt-ons to crazy track prepped super car slaying monster, we have the parts to complete your build. Listed below is a quick link overview of currently available IE products.

Recommended for OE - Stage 1 software and above
-IE FDS performance intercoolers

Recommended for Stage 2 software - K04 setup and above
-IE valve spring & titanium retainer kit

Recommended for big turbo setups and above
-IE H-beam "Drop-In" connecting rod set
-IE H-beam aftermarket piston connecting rod set
-IE performance rod install kit
-IE Spec Mahle piston set
-IE Sport Series assembled cylinder head
-IE performance valve guides

Chassis components
-IE adjustable FES camber plates

Billet Accessories
-IE Recirculating catch can kit
-IE billet valve cover breather plate
-IE billet boost tap
-IE billet boost cap
-IE billet diverter valve housing
-IE water methanol throttle plate
-IE rear breather block-off plate
-IE rear breather -10AN adapter plate
-IE secondary air injection block-off plate
-IE -10AN oil drain flange kit
-IE oil feed flange kit
 

Tyler@IE

Ready to race!

Below you will find expanded detail about all of the products listed above.

IE FDS PERFORMANCE INTERCOOLERS

The Integrated FDS intercooler system was built from the ground up to offer the ultimate in performance cooling for your vehicle. Our large 54% larger than the OEM intercooler core delivers cool air to the engine under all circumstances, increasing power and torque and simultaneously reducing heat soak.

The FDS advantage
Our end tanks feature the FDS (flow distribution system), which is totally unique to our intercooler. By incorporating flow distribution channels into the inlet side end tank, air is evenly distributed from the top to bottom of the core, maximizing cooling efficiency. Other intercoolers on the market only allow natural airflow through the core, which is primarily on the bottom side near the inlet, making for poorly distributed cooling. In lab tests, temperatures across the IE FDS core were 65% more even than the nearest competitor. This proves more effective use of the core, resisting heat soak more so than any competitor and consistently delivering a cool charge.

High performance, high quality cast end tanks
High quality American castings for the intercooler end tanks have perfect surface finish and absolutely none of the casting flaws commonly seen in import intercoolers which can destroy your engine. This attention to detail in the design process means that our intercooler is actually lighter than many import intercoolers, while simultaneously having a much larger core volume. These features provide an intercooler with perfect OE fitment and the utmost highest level of performance available today.

Perfect fitment
Our engineers also went to great lengths to ensure quality and perfect fitment. The end tanks were carefully CAD designed and CFD flow optimized. All mounting bosses are fully machined to ensure a perfect fit. Even the inlet and outlet barb connections are completely machined, ensuring a leak free seal. Learn more...

IE FDS Dyno data:



IE valve spring & titanium retainer kit

IE spring and retainer kits feature spring rates which are optimized to match your vehicle specifications and provide proper valve control even under high revving applications. Increasing your engines power output often comes with modifications that require more RPMs to get the most out of it, upgrading software and hardware components without changing out the valve springs can leave you with a short power band or cause valve float and other significant damage. Manufactured out of the best spring wire in the world IE valve springs use a patented multi stage shot peening process that further reduces failure rates. Our titanium retainers are machined with an excellent surface finish and tight tolerance control for a long lifespan. Learn more...

IE H-beam connecting rods

IE has remained the leading VW/Audi connecting rod manufacture with a history of high reliability on demanding power and strength requirements. This is accomplished through careful industry leading design practices, manufacturing, and strict quality control processes. For years our H beam rods have been the workhorse of our lineup providing excellent performance right out of the box. With very high reliability even in extreme applications our H beam design has remained the top choice in builds up to 700+ BHP, even found in four-cylinder cars into the 800+ BHP range. Extra attention has been paid to even the smallest details such as the bearing tangs, wrist pin fit, and big end side clearance. Each and every set is finish machined and honed in-house for perfectly round and on size big-end bores, resulting in the industry's lowest failure rates.

IE H-beam drop-in connecting rod set
Our specialty drop-in connecting rods are engineered with specific tapered small ends to match the OE piston design of the TSI engine. Learn more...

IE H-beam aftermarket piston connecting rod set
These H-beam connecting rods have perfectly matched small ends for use with aftermarket pistons on the 2.0T TSI engines. Learn more...

IE Performance rod install kit

To make the installation of your new Integrated Engineering connecting rod set a simple task, we have put together these performance rod install kits. These kits include all necessary OEM components needed for the removal and installation of the connecting rods, along with a set of Mahle Motorsport rod bearings and ARP head studs. Learn more...

IE Spec Mahle piston set

IE and Mahle motorsport has teamed up for several years now to deliver the highest performing and longest lasting forged pistons to match our connecting rods. These pistons are recommended for any high performance engine build, as they offer unparalleled strength and longevity. Designed with a proprietary factory-style dish on the crown with the factory 9.6:1 compression ratio, which is absolutely necessary for smooth operation with the direct injection system. Learn more...

IE Sport Series assembled cylinder head

The Integrated Engineering Sport Series assembled cylinder heads are designed to make meeting your performance goals hassle free, more enjoyable and easily attainable. Complete with all machine work and assembled with new performance valvetrain, ready to increase horsepower as well as support higher RPM levels. We have designed these with factory drivability in mind, taking care to build them with the proper components to offer smooth, quiet operation and the longevity you would expect from a brand new engine. As power levels increase over the course of your project, you can count on your Sport Series engine components to function reliably for years. Learn more...

IE performance valve guides

Integrated Engineering valve Guides are the performance option for replacing factory guides for new valves. Our valve guides are made from a specialized alloy on our in house CNC lathe with ultra high concentricity for exact valve placement and precise dimensions. Using a proprietary bronze alloy results in faster heat dissipation where thermal conductivity is increased by 10% and extends valve life, guide life, and cylinder head component life. For added performance, these valve guides have been designed with an aerodynamic tip designed to cut down on airflow restrictions in the valve port. Learn more...
 
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Tyler@IE

Ready to race!


IE adjustable FES camber plates

Integrated Engineering camber plates ensure your tire's contact patch is flat on the pavement under hard cornering. This is essential to maximizing grip levels dialing in the required amount of negative camber (leaning the tire in) for your specific tire and suspension combination. To ensure optimum performance, care was also taken to achieve these gains without any detrimental effects to daily drivability. A heavy duty spherical bearing controls the top of the shock absorber, coupled with a heavy duty thrust needle bearing as well. This has been taken to another level by our Full Environmental Seal technology (FES), completely sealing this bearing from the elements, eliminating the spring popping and binding issues common with many camber plate designs. Learn more...
 

Tyler@IE

Ready to race!


IE Recirculating catch can kit

Everything you need to upgrade the PCV system on engine is included with this kit, with a very simple installation that takes less than an hour to install on average. This kit allows the use of the factory engine cover if desired, and the entire install is completely reversible if it ever needs to be removed for any reason. Learn more...

IE billet valve cover breather plate

Designed to replace the plastic failure prone breather box setup, the internally baffled IE breather plate has the addition of two -10AN breather outlets allowing for the installation of a catch can to provide reliability by catching oil mist, PCV build-up, eliminates oil and water vapor from gathering in the intercooler piping and intake manifold, and reduces carbon buildup on the intake valves. Learn more...

IE billet boost tap

Installing a boost gauge or just need a vacuum source? Our boost taps will make this a breeze. They are offered in black or red anodize and included all necessary hardware, including a OEM retaining clip. Learn more...

IE billet boost cap

This boost cap is for use in applications when the OEM PCV system has been removed. It can also be used as a boost signal. This system ships with both a boost cap or tap depending on your needs, along with a new o-ring and retaining clip. Available in IE Red or black anodize finish. Learn more...

IE billet diverter valve housing

We are proud to offer the highest flowing diverter valve housing on the market for the 2.0T engines. These housings are used when installing a big turbo, or when simply doing the "S3" style relocation. The added flow of our housing is obtained by use of a 1.5" inlet with a built in bellmouth. Your factory electronic valve will bolt into our housing in any orientation needed. Learn more...

IE water methanol throttle plate

Make installation of your water meth kit a simple job. This plate gets sandwiched between the throttle body and intake manifold, allowing you to run a 1/8" NPT nozzle right after the throttle body. Manufactured from 6061 aircraft grade aluminum and finished with a bright black anodize. Kit includes all necessary extended hardware, and gasket for quick installation. Learn more...

IE rear breather block-off plate

This block-off plate is used when removing the rear breather from the factory turbo inlet. This is typically done when installing a billet valve cover and/or a custom catch can setup and the factory line from the valve cover is removed. Learn more...

IE rear breather -10AN adapter plate

This -10an breather adapter plate is used when removing the rear breather from the factory turbo and replacing it with -10AN male threads, typically used in recirculating catch can setups. learn more...

IE SAI block-off plate

These plates allow the removal of the entire secondary air injection / combi valve system, including the large injection pump near the oil filter. This results in a much cleaner looking engine bay, as well as less clutter and more room. Includes aerospace grade Viton O ring, and stainless steel socket head hardware. Not recommended for street driven cars. Learn more...

IE -10AN oil drain flange kit

When running a custom big turbo setup, this flange makes plumbing a -10AN oil line simple. Complete kit includes adapter flange, o ring, and two stainless steel bolts. Learn more...

IE oil feed flange kit

When installing a custom big setup, you will need to plumb a new oil feed to your turbo. This is not possible with the OEM feed flange and factory hard line. Our adapter fitting kit will make the conversion easy by replacing the factory hard line on the back of the engine block with a male -4AN fitting. Learn more...
 

Tyler@IE

Ready to race!


IE Performance Software Tuning

Integrated Engineering has become well known for attention to detail, high quality, and perfect fitment of performance hardware and engine products that we offer. To complement our quality products, we have developed a line of performance software, which incorporates the same attention to detail and enables IE to offer a complete performance package. Our engineers start by completely reverse engineering each specific ECU, which is used to then develop performance software for that application. With use of our in-house Dynapack DP42 dynamometer, we are able to do repeated runs to test each change that is made to the software and confirm drivability. TSI Stage 1, Stage 2, and matching IE big turbo kit files are currently in the works.

IE 2.0T Performance Intake Manifolds

You can expect large gains when swapping your factory intake manifold to an Integrated Engineering unit. A factory manifold is designed to channel air into the engine sufficiently well to meet the original horsepower targets, while being cost effective and quick and easy to install. This compromise means that there is room for significant improvement on many VW/Audi models. Our manifolds are designed from the bottom up to put performance first. They exploit careful tuning of the intake manifold runner lengths and diameters to create a resonance effect which rams more air into the cylinders. Each plenum and runner is carefully optimized with computer software for maximum flow in the specific application that it was designed for. IE's TSI intake manifolds design has been finalized and is currently in production.

IE450T big turbo kit

The IE 450T big turbo kit is a complete turbo upgrade system based on a twin-scroll BorgWarner EFR turbocharger, which offers larger power gains than other kits on the market, while offering faster spool time. Included with the kit is everything needed to upgrade, including hardware and software. In bolt-on form, the kit will increase horsepower to 450bhp on stock engine internals, with the capability of over 500bhp if a built engine is utilized. Although the kit currently in production is for the Golf R's FSI engine, a MK6 TSI version is on the drawing board. Read more about our exciting new turbo kit on the IE blog HERE.

IE 2.0T intake kit

To accompany our intercooler kit, upcoming software, and even our 450T big turbo kit, we have developed our own intake kit. After testing many competitor designs, we have found much of the aftermarket intakes currently available completely alter the factory mass air flow sensor scaling, causing haywire and power loss on otherwise high flowing components. Our design retains the factory MAF scaling while increasing the flow with larger mandrel bent powder coated piping, reinforced silicone couplers, high-flowing velocity stack, massive IE filter, and black powder coated heat shielding. Coming soon!
 

Tyler@IE

Ready to race!
We want to formally congratulate James Castellano and CSP for setting another VW record by going 8.92 at 172 MPH! Check out the IE blog for more photos and info on this impressive car utilizing Integrated Engineering 2.5L engine parts.

 

AXO

Go Kart Champion
If that intake manifold is priced right, I don't think you will be able to keep them on the shelf!!! Please make enough for everybody!!!!!
 

Tyler@IE

Ready to race!
So you guys want intake manifolds? lol

We are actually expecting the final cast sample any day now, once we sign off on final fitment, quality control, and power testing then we can start a pre-sale. These are very close now!
 
Intake manifold doesn't make any difference, few people have already posted about it... It's not restrictive like for the FSI engines... Sure it looks great, especially with the holes ready for m but that's an expensive part for just the look ;)
 

greasyginzo

Go Kart Champion
So the TSI turbo kit is only on the drawing board? Meaning what exactly? Are you guys still working out if it is feasable and/or doable? It is my opinion that you guys would sell a hell of a lot more TSI turbo kits (especially using the EFR turbos) then FSI kits since the market is flooded with FSI BT kits and most of the Golf Rs interested in a turbo kit are already APR stage 3. IMO it is the TSI market that is looking for a packaged BT kit with software that makes decent to big power since the only other option is APR and we know how dissapointing those kits are.
 
So the TSI turbo kit is only on the drawing board? Meaning what exactly? Are you guys still working out if it is feasable and/or doable? It is my opinion that you guys would sell a hell of a lot more TSI turbo kits (especially using the EFR turbos) then FSI kits since the market is flooded with FSI BT kits and most of the Golf Rs interested in a turbo kit are already APR stage 3. IMO it is the TSI market that is looking for a packaged BT kit with software that makes decent to big power since the only other option is APR and we know how dissapointing those kits are.


I'm sure hardware is not the problem, it probably could be out already... They should release the kit without software, med 17 is way more complicated than others ECUs and it will take them ages to figure it to finally have a tune that's probably not even that great..
 

greasyginzo

Go Kart Champion
I'm sure hardware is not the problem, it probably could be out already... They should release the kit without software, med 17 is way more complicated than others ECUs and it will take them ages to figure it to finally have a tune that's probably not even that great..
I know
 

ErBall

Measurement Mogul
All I care about is auxiliary fuel injector ports on the intake manifold. Having proper fueling support will be grand.
 

ViRtUaLheretic

╭∩╮(︶__︶&#6
So im drawing a blank, where does the rear breather adapter mount to on the TSI engine?
 

Tyler@IE

Ready to race!
Intake manifold doesn't make any difference, few people have already posted about it... It's not restrictive like for the FSI engines... Sure it looks great, especially with the holes ready for m but that's an expensive part for just the look ;)
That may be true for the other products on the market, but we have shown very good gains even on aggressive K03 and K04 setups with our design. Larger turbos of course take much more advantage of the manifold. Proper resonance tuning and runner shapes coupled with flow tuned velocity stacks and plenum volume/shape goes a long way. We did not rush this product to the market, even though the demand has been incredibly high to ensure it was an actual performance piece. We have been developing the highest performing intake manifolds on the market for quite some time now. We are compiling all the engine and chassis dyno data now to release with the pre-sale.

So the TSI turbo kit is only on the drawing board? Meaning what exactly? Are you guys still working out if it is feasable and/or doable? It is my opinion that you guys would sell a hell of a lot more TSI turbo kits (especially using the EFR turbos) then FSI kits since the market is flooded with FSI BT kits and most of the Golf Rs interested in a turbo kit are already APR stage 3. IMO it is the TSI market that is looking for a packaged BT kit with software that makes decent to big power since the only other option is APR and we know how dissapointing those kits are.
Hardware. The hardware is very similar for both cars, but the TSI kit requires a few different cast intake and charge piping, silicone, downpipe, and a few other odds and ends. The casting process is the longest wait for the whole turbo kit, but it is in the works now and we are pushing to release it quickly after the Golf R kit.

I'm sure hardware is not the problem, it probably could be out already... They should release the kit without software, med 17 is way more complicated than others ECUs and it will take them ages to figure it to finally have a tune that's probably not even that great..
Actually as posted above it really is just the wait for hardware on these. We have great success in tuning these ECU's, only real road block with the software side is not tuning it, but delivering it without having every customer mail in an ECU for bench flashing on MED17 platforms. However, we are now working out what we need to deliver these via port flashing.

We have been tuning up to 5 local VW and Audi TSI cars a day for Stage 1 - 2 tunes for months now for verification all the different ECU codes. Our tunes are holding their own against any other.

Here are early TSI tune revisions (we are at 4500 feet here, not sea level).



All of our 2.0T Stage 1-2 tunes are about to go for sale soon as well. We are actually planning a trip very soon to take our EFR kits through a long road trip through high elevation mountains, hot desert, heavy traffic, and sea level through California to show how well our tuning will perform in any area. We will have lots of video, photos, and data for that.

So please, don't worry about software. Cracking MED17 was absolutely no issue.

All I care about is auxiliary fuel injector ports on the intake manifold. Having proper fueling support will be grand.
All the manifolds will come designed with plenty of room for fuel injectors, and will be delivered with tapped 1/8" NPT threads for water meth injectors. For those few really pushing the boundaries of fueling that want manifold injection, we left a lot of room for injector ports to machined in by any machine shop.

Are those top mounts for meth injection or fuel injectors?
They will come tapped for methanol, with plugs in them for those running either. For those few customers who want manifold injectors, there is plenty of room to have bungs machined in.

So im drawing a blank, where does the rear breather adapter mount to on the TSI engine?
It replaces the rear breather on the back of Garret turbos. However if you are using the valve cover breather plate to setup a catch can, you do not need that piece. Only those running the early single outlet breather plates would need this piece.
 
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