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    VWVortex


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    Thread: 2.5L AAF engine mods

    1. Junior Member BigDan1's Avatar
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      westfalia 94, dodge magnum RT 2005, olds cutlass 1984 restomod
      03-27-2012 04:19 PM #1
      my gas 2.5L vw engine was due for a timing belt replacement ,so I removed it from the eurovan ... just took my cyl head off ...plan to shave .040 to obtain 9.5 cr instead of the original 8.5 ....
      head will be ported also ...
      my main problem is the exhaust manifold ,,,it has a bellow between no:2 & 3 cylinder ...causing a major restriction ...is there any year that had a better tubular manifold ..
      thanks ,
      Dan
      ProPerformance ....engine mods at honest prices ....
      94 westfalia ,2.5L gas engine ,
      Olds Cutlass 84 restomod LT1+700R4 + 9" diff ......
      CJ-7 Jeep modified 250hp 4.0L + AX-15+ dana`s 44 ,4;10 , both lockers
      Dodge Magnum RT AWD 2005 .....lots of toys !

    2. 03-28-2012 02:09 AM #2
      Yup, the 1995 ACU engine's manifold. Problem is, the outlet is a dual-outlet six-bolt arrangement which means swapping the downpipe too.

    3. Junior Member BigDan1's Avatar
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      westfalia 94, dodge magnum RT 2005, olds cutlass 1984 restomod
      03-29-2012 04:49 PM #3
      I`ll get the down pipe at same time then !


      just cant remember where i saw someone do all those mods to a 2.5L and gained 20 hp ...
      ProPerformance ....engine mods at honest prices ....
      94 westfalia ,2.5L gas engine ,
      Olds Cutlass 84 restomod LT1+700R4 + 9" diff ......
      CJ-7 Jeep modified 250hp 4.0L + AX-15+ dana`s 44 ,4;10 , both lockers
      Dodge Magnum RT AWD 2005 .....lots of toys !

    4. 03-30-2012 02:10 AM #4
      Unfortunately both parts are a bit pricey new.

      It was someone on this forum though. I think he had a red '93 that he put the ACU manifold and downpipe in as well as some other mods like polishing the intake or something like that.

    5. 03-31-2012 12:46 PM #5
      Quote Originally Posted by gti_matt View Post
      Unfortunately both parts are a bit pricey new.
      http://www.worldimpex.com/parts/genu...ol_127007.html
      http://www.worldimpex.com/parts/genu...ipe_40038.html

      Quote Originally Posted by gti_matt View Post
      It was someone on this forum though. I think he had a red '93 that he put the ACU manifold and downpipe in as well as some other mods like polishing the intake or something like that.
      http://forums.vwvortex.com/showthrea...7#post70571917

      (Pics gone from there but they WERE in there)

      Header pic:


      For ref the cast iron version:

    6. 03-31-2012 02:16 PM #6
      Europarts $140 cheaper.
      http://store.europarts-sd.com/exhaus...1995-1996.aspx

      Can't find that one on Europarts' site now but used to be there. Not sure what happened to it. Maybe I'm not searching on the right keyword...?

      Quote Originally Posted by EV99 View Post
      [url]
      Header pic:


      For ref the cast iron version:
      Yep, note the different bolt connections for first exhaust pipe, hence why you need that too.

    7. 03-31-2012 05:11 PM #7
      Quote Originally Posted by gti_matt View Post
      Yep, note the different bolt connections for first exhaust pipe, hence why you need that too.
      Heh I had saved the pic of the red one:

      Last edited by EV99; 04-01-2012 at 01:32 PM.

    8. 04-01-2012 02:22 PM #8
      Yep that's the one I remember (I remember it was a red van and red valve cover).

    9. Junior Member BigDan1's Avatar
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      05-02-2012 01:36 PM #9
      finally got a 96 manifold + down pipe from just around my place at a good price ....

      my cylinder head is ready to reinstall ( pic soon)

      Can I reuse the original bolts ?
      ProPerformance ....engine mods at honest prices ....
      94 westfalia ,2.5L gas engine ,
      Olds Cutlass 84 restomod LT1+700R4 + 9" diff ......
      CJ-7 Jeep modified 250hp 4.0L + AX-15+ dana`s 44 ,4;10 , both lockers
      Dodge Magnum RT AWD 2005 .....lots of toys !

    10. 05-03-2012 01:21 AM #10
      Nope. Cylinder head bolts are stretch bolts and should not be re-used. Gotta get new ones.

    11. Junior Member BigDan1's Avatar
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      westfalia 94, dodge magnum RT 2005, olds cutlass 1984 restomod
      05-03-2012 08:43 AM #11
      ARP doesnt make any new ones ....

      dealer only ?
      ProPerformance ....engine mods at honest prices ....
      94 westfalia ,2.5L gas engine ,
      Olds Cutlass 84 restomod LT1+700R4 + 9" diff ......
      CJ-7 Jeep modified 250hp 4.0L + AX-15+ dana`s 44 ,4;10 , both lockers
      Dodge Magnum RT AWD 2005 .....lots of toys !

    12. 05-03-2012 06:43 PM #12
      Quote Originally Posted by BigDan1 View Post
      ARP doesnt make any new ones ....

      dealer only ?
      Cylinder head bolts? europarts-sd.com has them. I got mine there.

    13. Member
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      92 Eurovan LWB, 95 Passat GLX wagon
      05-27-2012 04:03 PM #13
      Anyone have a picture of the downpipe for the ACU manifold?

      I found one on google of both together, but a close up of the downpipe alone would be great!
      Last edited by Kwabena; 05-27-2012 at 04:22 PM.


    14. Member
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      92 Eurovan LWB, 95 Passat GLX wagon
      05-29-2012 10:40 AM #15
      I found that one the other day.
      Thanks though!
      It's pretty good.
      Wanted one with just the downpipe.
      My mechanic in Ghana has found me the manifold, but now is looking for the downpipe and wanted a good pic...

    15. 05-29-2012 01:27 PM #16
      Quote Originally Posted by BigDan1 View Post
      my main problem is the exhaust manifold ,,,it has a bellow between no:2 & 3 cylinder ...causing a major restriction ...is there any year that had a better tubular manifold ..
      I hadn't noticed before but note that the ACU manifold has it's own version of some sort of accordion-flex thing (although it looks welded in?) between the #1 cylinder's tube and the exhaust outlet too.

      It's likely to flow better I guess but still has some limitations. The biggest gain with this one is that so far it's not known to suffer the same failures as the AAF manifold.

    16. Junior Member
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      '93 EV
      05-29-2012 07:57 PM #17
      Anybody know the I.D. of the tubing on the '95 manifold?

    17. Member
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      06-02-2012 10:41 PM #18
      I can measure it, but I can tell you from the one that I have that it is very small, and looks like it does not flow well at all.

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