Integrated Engineering MK6 Golf R Product Overview

In this post we will go into detail on what IE manufactured products we have to offer, and what power stage each product is best utilized.   We will also use this post to 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.

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. 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 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. 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 Intercooler Dyno graphs:

 

 

The high pressure fuel pump is cam-driven providing over 1500psi to the direct injection fuel injectors in the FSI engine. More fuel is required to support the added horsepower from larger turbos, ECU tunes, and other power-increasing modifications. IE HPFP utilizes an increased bore size of the Nitride coated cylinder, coupled with our Nitride coated constant diameter piston resulting in 50% more displacement than the factory unit. This combination offers fueling for nearly 600hp at 7500rpm. This is a great reliable performance upgrade for those looking to do a big turbo setup, or even max out the factory turbo at higher boost levels. 

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.

IE H-beam connecting rods (Designed for use with aftermarket piston sets, Mahle and JE designs available)

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 industries lowest failure rates. These H-beam connecting rods have perfectly matched small ends for use with aftermarket pistons on the 2.0T FSI engines.

IE Tuscan I-beam connecting rods (Designed for use with aftermarket piston sets, Mahle and JE designs available)

IE's Tuscan I-beam connecting rods are the best rods available for your engine. Each individual engine application has been custom-crafted and optimized by our engineers. IE's own I-Beam design as been utilized for incredible bending and torsional stiffness. Additionally, an extensive iterative process lead to the unique Egg shape of our rod beams, which lowers stresses as much as 20% compared to less evolved designs. This shape very evenly distributes the high compressive loading from a turbocharged engine onto the connecting rod beam. We then validated this success with years of field testing, powering numerous 4 cylinder VW / Audi engines with over 1000 bhp! In addition to being tough, IE Tuscan rods are also designed to minimize unnecessary weight on the connecting rod for an ultra balanced weight to strength ratio.

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 components needed for the removal and installation of the connecting rods. Available in a basic or ultimate kit.

IE Sport Series assembled short block

IE precision shortblock assemblies are the strong and reliable basis for your high performance engine build. Every short block option underwent countless hours of engineering and torture testing on our in-house dyno facilities to determine the best selection of parts and build specifications for the performance level. This extensive design and testing process ensures your new short block assembly will perform with the upmost reliability. Your Sport Series short block is completely inspected, machined, and meticulously assembled with IE Tuscan I beam connecting rods, Mahle 83mm bore 9:1 CR forged pistons, OEM main bolts, OEM thrust washers, and Mahle rod & main bearings.

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.

Advancing or retarding your cam timing allows you to adjust your power band for peak power. IE cam gears are precision CNC-machined from solid 6061 aluminum, and feature a real one-piece male keyway for an exact OE fit with no concern of failure. The cam gear outer rings are machined to OE specifications for a perfect mesh with your timing belt, featuring a hard anodized finish for minimal wear. The threads are roll-form for solid engagement, then stuffed with high quality stainless ARP bolts to lock it all together. Finally, a flawless layer of bright dip anodizing is laser-etched so you always know exactly where your cams are positioned.

Eliminate the weak design of the factory drive gear keyway once-and-for-all with the IE billet replacement. The factory gears are notorious for breaking keyways and crank bolts coming loose with aftermarket performance upgrades, causing timing belt failure. IE press fit gears have completely redesigned the factory interface, removing the weak factory gear and loose-fitting keyway, replacing it with a precision machined and zinc plated solid steel gear with a press-fit interface.

IE Race Engines has developed the highest flowing, best performing CNC ported cylinder head design available. Featuring ports developed in partnership by a 30 year porting veteran who has worked for NASCAR, OE performance development models, and worked with a vast array of professional racing projects. Each port is the product of hundreds of flow bench pulls. Variables such as port shape, valve guide length and shape, valve shape, valve job angles, and many more are all checked and rechecked, until the final port design is manufactured to exacting details among all ports on a 5 axis CNC machine. Each head also receives IE's own complex LiftMAX valve job. This valve job optimizes flow in low valve lift conditions seen in these applications. Heads are checked for material integrity, soda blasted, ported, and assembled with new IE racing valve guides, making for a complete performance package. Available bare or assembled

Under high RPM and power use your block can begin to flex, causing severe main bearing wear or even a broken crank. Reinforcing the block is a necessity for these extreme applications. This girdle kit uses a 3/8” steel plate sandwiched between the block and oil pan using supplied ARP hardware to reinforce the block and prevent flexing under high power use. This kit includes all lengthened hardware needed to install the girdle plate. This kit will remove the factory balance shaft/oil pump assembly, and replace it with a chain driven oil pump. Available in a basic kit using OE main caps and spacers, or ultimate kit utilizing IE "tall boy" main caps.

Your factory main caps were designed to handle only the power output and RPM level of a stock engine. On high horsepower applications, OE cast main caps can stretch and become distorted causing serious damage to main bearings or crankshaft. IE billet main caps eliminate the chance of main cap failure using 4140 in house machined steel main caps. Available as direct OE replacements or "Tall Boy" main caps for use with girdle plates.  (Requires machine work to install)

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.

 

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.

 IE recirculating catch can kit

IE billet valve covers start off as one large piece of 6061 aircraft aluminum, and are precisely machined on an in-house CNC mill. They are a direct replacement for your factory valve cover, and use the OEM gasket. They have a single -10an outlet for a custom breather setup. To ensure that no oil comes out of the breather, these have welded baffles that are guaranteed to not fail. In place of a factory oil cap, these use a billet aluminum cap with an o ring for a tight seal (Requires IE EVAP crossover relocation kit and custom catch can kit to install)  

The factory pressure-relief valves are in place to recirculate crankcase gases into the intake manifold, over time they can beg into leak, a faulty valve can cause boost leaks, creates an oily mess, rough idle, fuel economy decline, and power loss. IE's billet solution includes everything needed to completely remove the pressure-relief valve and replaces it with a billet aluminum plate. This allows the factory breather system to function properly, while eliminating the failure-prone relief valve. 

Similar to the PCV solution plate, the IE valve cover breather adapter replaces the failure prone OE factory PCV valve with a billet plate, however this solution has the addition of two -10AN breather outlets allowing for the installation of a catch can to provide further reliability by catching oil mist and PCV build-up. 

When installing a catch can, adapting the factory breather hose is not possible without many ugly fittings and a ton of work. We manufacture these block breather adapters in-house providing a direct fitting replacement with a male -10AN outlet. This fitting clips to the factory plastic oil filter housing with use of the included metal clip and o ring for a leak-free seal. 

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. 

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. 

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. 

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. 

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.

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.

When exceeding the limits of the stock high pressure fuel pump system on very high horsepower builds, some may require custom setup manifold port injection. We have manufactured this block off plate to take care of the hole left from removing the HPFP. These are a direct fit, with an O-ring seal to ensure a leak free connection.

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. Golf R Stage 1, Stage 2, and matching IE big turbo kit files are currently in the works.  

The IE 450T MK6 Golf R 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. 

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 2.0T intake manifold design has been finalized and is currently in production.  

To accompany our intercooler kit, HPFP, 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!