APR Carbon Intake System – MQB 1.8T/2.0T EA888 Gen.3 – CI100033

The APR carbon fiber intake system is an attractive high-performance upgrade for the latest 1.8T and 2.0T engines found in several MQB platform vehicles. The factory intake design has the foundation for excellent performance, but much of that is sacrificed in an effort to meet other design requirements. With the requirements set to support only factory power levels, low engine noise levels, and long service intervals, there is plenty of room for improvement. The APR carbon fiber intake system increases performance primarily by improving mass airflow through the system while also providing adequate filtration. Expect increased horsepower and torque across the powerband with a more direct and responsive feel when pressing the throttle. Engine and turbocharger sounds are improved, and some may even experience better fuel economy depending on driving style.
ae torque
Better throttle response
Improved engine sound
Closed carbon fiber system
All mounting hardware included
Pleated cotton gauze filter
Directional rotating vanes for proper filter loading

RESEARCH AND DEVELOPMENT
Unusual for most in the market today, APR spared no expense during the research and development period. For the better part of a year, APR’s mechanical engineers created several prototype intake designs utilizing our in-house sterolithography 3D printer and other rapid prototyping techniques. Various filter media were tested in conjunction with the new intake designs through simulated models, flow bench analysis, dynamic data collection, and in real-world applications, all in an effort to achieve the best possible solution. To increase performance over the stock intake system—the intake system’s ability to flow a larger mass of air—APR’s mechanical engineers focused on improving the pressure ratio between the intake system inlet and outlet, reducing turbulence, maximizing filter efficiency, and keeping IAT as low as possible.

IMPROVING PRESSURE RATIO
In an effort to achieve an ideal pressure ratio (1:1) between the intake inlet and outlet, the intake features several key features. Through CFD optimization and flow bench validation, the intake filter housing has been shaped into a reducing spiral, or volute, which utilizes the inertia of the air entering the system to increase pressure on the outside of the filter. This creates an even distribution of pressure across the entire face of the filter, rather than just at a few key points, and as such, maximizes the utilization of the filter element. Compared to many other popular intake styles, the APR intake system allows for the use of a small, compact filter that is more than twice its size. Unlike traditional open element filters, the APR intake design only draws air from the grille area near the front edge of the vehicle’s hood. In doing so, it draws air from a relatively high pressure area. As vehicle speed increases, pressure continues to increase, ultimately aiding in the efficiency of the intake. By sealing the intake system, the pressure created during the effect of compressed air and the volute design is not simply lost within the engine compartment. This is in contrast to open element filters which draw air from a relatively low pressure region formed within the engine compartment.

REDUCING TURBULENCE
Flow disruptions and turbulence impede airflow to and from the intake filter, resulting in loss of performance. The APR intake system takes a two-step approach to improving mass airflow in this region. As the air directional vanes travel, they ensure that the airflow is properly directed across the entire length of the intake filter, rather than just a small portion. This results in reduced air turbulence and creates an even distribution of pressure across the entire filter surface for maximum filter efficiency. As the filter becomes dirty over time, the drop in performance occurs less dramatically, as particles form evenly across a larger portion of the intake, rather than localizing in one location or another. When air flows through a smooth tube, the velocity at which the air flows is slower along the smooth walls of the tube than in the center of the tube. This ultimately results in a boundary layer that effectively reduces the cross-sectional area of ​​the free-flowing portion of the tube and creates drag. To minimize this effect as much as possible, the inner surface of the inlet is kept slightly rough during the manufacturing process. As such, it becomes thinner, which ultimately prevents the boundary layer from growing as the flow increases.

INTAKE AIR TEMPERATURE MANAGEMENT
Intake Air Temperature (IAT) plays a critical role in engine performance, especially on turbocharged engines where the ambient air temperature is raised twice during compression through the turbocharger and again during the engine's compression stroke. In an effort to keep the initial IAT as low as possible, the APR intake system begins by drawing air from the coldest possible location, which is the front end of the vehicle before the radiator. The air travels a short distance through the intake system, past the filter, and on to the turbocharger through a sealed intake design that prevents hot air from being sucked under the hood. Finally, the intake's carbon composite design features a thin fiberglass strut, which improves thermal insulation properties. NOTE: By contrast, the APR system does NOT block the factory engine cooling duct found on the opposite side of the factory intake system.

FILTRATION
APR’s design requirements required an intake filter media that would provide high flow capacity, long service life, and adequate filtration properties. While traditional paper filters and even some foam filters can meet one or more of these requirements, only a pleated cotton filter was able to meet all three. This is due in part to the volute design and rotating vanes of the intake housing. By distributing pressure flow evenly across the filter element, the filter is loaded more evenly, maintaining performance over time, extending maintenance intervals, and increasing filter effectiveness.

SOUND
In an effort to please customers unfamiliar with the sounds caused by turbocharging a cross-turbocharger in both economy and performance-oriented vehicles, the OEM was tasked with creating an intake that many would consider too quiet for a high-performance vehicle. APR's design requirements called for an intake system that would only deliver the engine's true turbocharged sound when air was sucked in by the turbocharger or exhausted through the diverter valve when the throttle was lifted off. The inherent rigidity of the carbon fiber composite material results in an engine induction resonance, allowing occupants to hear a clean, crisp intake note without sounding overbearing or cheap.