I finally got around to completing piecing together and installing my intake modification for my 05 Turbo.. Just curious if anyone else has similar experience.


1) Massive induction noise increase at part throttle/low rpm. Lot of spooling sound, I can hear it over the radio at low speeds. Its MUCH louder than I thought it would be. I think it sounds quite nice to be honest


2) Similarly loud increase in noise from the diverter valves. It sounds similar to past cars Ive owned with vent to atmosphere blow off valves. Its audible from outside of the car as well. Definitely did not expect to have these sounds coming from the Cayenne!


3) Part throttle response and spool up is much better. It feels like the midrange has gained a lot of power/torque. Worth it just for these gains alone.


4) I don't really feel much difference in top end/high rpm power at all...


Anyone else have any impressions?


The little to no gain in high rpm is leading me to believe that there is another bottleneck in the system somewhere that is reaching max cfm somewhere in the midrange rpms. Maybe the intake manifold/throttle body, maybe the factory 955 intercoolers or the piping...

 

What did you end up doing? Cold air intake? I'd love to do the entire intake from the intercoolers up. Like what Kent did. Had mine torn apart this weekend attempting the power steering pump but ended up putting it back together last night before finishing. Frustrating to say the least.

I still have the 957 intake here. I don't think I'm going to get to doing anything with it soon at the rate I'm going. I think you are right that the pipes from the intake and the throttle body itself are the next bottle necks.

I'm hoping I got most of my vacuum leaks fixed and the boost gauge at least is showing I did. Back up to 13+lbs.

 

Yeah I built my own intake system from the MAFs forward. I think my next step in the intake path is going to be moving from the intake side of the turbo piping to the intercoolers then up to the TB/intake manifold.. Just not sure where I want to begin or what path to take. Actually, I may go for primary downpipes the more I think about it. So many things I'd like to do.


That's awesome that you are seeing the higher boost again. What was it seeing on the dyno?


Speaking of boost, something I noted after making the post yesterday and may explain why I feel a big midrange gain is that mine will peg the boost gauge for just a moment before it settles down to what was the peak boost prior to the intakes.. Then it holds there and drops slightly as it approaches redline, just as its always done. So midrange is seeing a bit of increased boost. Not sure how I missed that when I did my initial driving, but Ive confirmed it wasn't a fluke because its done it every time that I've watched it. Even on part throttle the boost spikes higher than it used to. Im enjoying this mod just as much as the secondary pipes. Its much smoother acceleration as well. Have you done intakes on yours?

 

I put K&N filters in but that's it. Did you make your own CAI or buy one? I like the idea of opening things up even more.

I think there is probably more to be gained by opening up from the intercooler up to the throttle body. The plastic pipes restrict things down quite a bit it seems to me. Of course then a bigger throttle body would be the next step. Just need to frankenstein something to our manifold to make it work.

 

I made one. Incredibly easy to piece together. Took some measurements, ordered a few parts from Amazon, did some more measuring and trimming/cutting.. I spent less than 2 hours total time and saved a good bit. The most expensive part was the filters.


I 100% agree about more to be gained by opening it up between the intercoolers and the intake manifold. I feel like that's one of the biggest advantages the 957 has over the 955 when it comes to modifying.. Intake and turbos are much more capable than what we have.

 

Well hook a brotha up with some details. I love Amazon. I need to look at picking up a larger throttle body then I can start looking at cutting and grafting something together for the intake.

Might just peruse Kent's thread on the intake piping and Y. I don't' have a welder but could fab it up ok and take it somewhere. Got me thinking now.

 

I'll PM you the details with some links since I don't want to step on any sponsors toes or have anyone think Im trying to market a "SeattleTurbo CAI"


I keep going back and forth with what I want to do as far as intercoolers and piping. I really need to get in there and take things apart and start measuring and see what Im willing to cut.. I think I can get more cooling capacity, and less piping/less bends (greater flow), for less money, by going with a front mount and eliminating the side mounts, and then in the place of the factory sidemounts, run direct piping from the turbo intakes to the side inlets rather than going up down and all around into the fenders. The piping between the turbocharger and the MAF is surprisingly restrictive, way smaller than I expected, and the whole pre-turbo intake track has a lot of bends/restrictions so I think there are definitely gains there, Im just not sure how much or if its worth it.

 

I would love to know more about what you have done so far. Maybe even a few pictures.

 

I'm waiting on a final part that I've decided could be an improvement. Once I have that in and done (hopefully this weekend/early next week), I'll post some pictures and a write-up if it doesn't violate the rules of the board.


All I've built so far is from the MAFs forward, if you're interested in that shoot me a message and I'll share more details

 

Would really appreciate some pictures and info on this mod.

 

Hi,

Updates on your last minute add on? Details on what you ordered and what you did as well as pics hopefully - eagerly looking forward to updates.

Thanks in advance,
Keoni.

 

Definitely interested, please post details and pics!

 

Ive been off the forums a bit lately, but I've still got them in the car and its doing great. Probably my favorite modification.

What kind of questions do you guys have and what specific photos do you want?

I only have this low-res photo on my work computer, but I can get specifics with better quality if needed.

 

Seattle,

thanks for the picture, looks great - the questions we have is you mentioned you'd do a write up and we were waiting for that: what did you order, types, bends, which filter and size, what was the last minute change.

The basics of a DIY intake. I intend to do one as well however this is my daily driver but maybe this weekend I'll take it apart to get an idea of what to order and such.

Thanks.

 

My last minute change was I used a larger filter, about twice the size as most intakes (more filter area = more cfm) and I wanted to make sure it would fit. I did make it fit, but it was probably a lot of effort for minimal gains, if any. I'm also working on ducting cold air into the filter area, but I haven't really done much with this yet other than measure and brain storm.

Im going to give this a quick write up to get everyone that is interested in doing this started, I can follow up with more clarification if anyone needs it. I take no liability for any damage or harm you cause by following the path that works for me, everyone's experience may vary. I'm away from the car until the weekend so pics will have to wait, but I will add them later.

Parts (I have linked to what I purchased, I am not affiliated with or receive any endorsement from any of these manufacturers or companies, this is simply what I used in my project)::::

-2 quantity 90 degree silicone reducer elbows ( )

-2 quantity 90 degree 4" aluminum mandrel bends ( )

-2 quantity air filters (http://smile.amazon.com/gp/product/B...ilpage_o09_s00 ) ****NOTE ABOUT THIS FILTER; this is the one I used. This larger filter does not fit easily. I had to cut the aluminum bend short to make this fit, and it still barely fit; It will make the project much simpler to use a filter size similar to the other intakes on the market especially since Im not sure that the larger/higher cfm filter even makes a difference. The bottleneck is further down in the intake system after the MAF.. http://smile.amazon.com/Spectre-Perf...let+air+filter I did a quick search and found this one that will *probably* fit much easier, but I can't guarantee it since I did not use it. This second filter is 6.7" length compared to 11.4" for the one I used; When I was testing my setup before using the larger filters, I just used a pair of mismatched random 4" inlet air filters I had in my garage left over from other cars)

-You will need 4 hose clamps (I used T-bolt clamps because that's what I had in my garage)

-You may elect to install a breather filter on the line going to the air suspension. I ziptied it up and out of the way and have had no negative effects.

-You may want to fabricate a heat shield; I did not. I worked on a design to add a carbon heat shield to mine and measured temperatures at the air filter with and without a heat shield under various driving conditions, and there wasn't enough difference (less than 1 degree at the filter) to make it worthwhile for me. I think the best difference in reducing intake temperature will be when I finish my cold air ducting.

Tools needed:
I need to check on this and get back with you guys, I will update it once I look it over. It wasn't anything out of the ordinary and you will probably already have it in your garage if you have been wrenching on your Cayenne before.

Installation:
***Im going to assume that if you are piecing together your own intake, you are somewhat mechanically inclined, so I may leave out some steps that are obvious since I'm not walking this through bolt by bolt, again anything you do is at your own risk and I'm going to touch on the overall procedure and what I remember the trouble points to be***

First thing you want to do is remove all of the factory stuff (obviously).
Start with the airbox and work towards the turbo; I don't remember the airbox being too difficult, but removing the headlights make it much easier to do. The passenger side airbox has the connection for the air suspension, its a kind of tricky connection. There is some wrestling required to get the airbox out of the fender. If you need to be walked through bolt by bolt on removing this, follow this guide http://quvpr.powmx.servertrust.com/v...ow_Install.pdf through step 7.

After this is complete, you are going to need to remove the MAF and it's housing piece from the turbo inlet pipe (there is a small worm clamp just below the MAF connection). I found it very easy to damage this plastic pipe below the MAF, I think its brittle from the heat over the time because on one side when I pulled the MAF out the flexible section of the inlet pipe came off with it and I had to source another turbo inlet pipe. Proceed with caution.

Once the MAF is out, install the small end of the silicone reducer goes to the MAF section, then put the MAF and reducer back to the factory turbo inlets. Next you have to get that 4" aluminum bend into the 4" side of the silicone coupler. Angle the pieces to get it positioned correctly so the stock plastic cover fits back on it, then add the filter on the end.

I don't have the step by step pictures or anything like that, and like I said I'm away from the car until the weekend so pictures will have to wait until after I'm back to get specifics.