Revo Open Cone Air Intake System
OEM VS REVO
When enhancing the performance of the 2.0T EA888 Evo low output engine with software, the restrictive OEM intake struggles to flow enough air and limits the potential power gains from performance software. The Revo Air Intake System removes these restrictive elements, flowing more air volume and promoting smoother airflow vs. the OEM system. The Revo Open Cone system replaces the OEM air box with an aluminium heat shield and open cone filter to provide the aggressive intake/turbo sound and massive flow gains over the OEM air box filter. Aluminium, powder coated piping and the Revo machined turbo inlet connect to the Revo Flush Fit silicone hose, which avoids unwanted turbulence at joints and increases the rate at which air can flow through the hose. The size of the Revo components and the Flush Fit hose design ensure maximum air performance at any level of tuning.
No detail has been overlooked in the Revo open cone Intake to reduce intake system restrictions. The stock corrugated plastic hose is replaced with a larger, internally-smooth silicone hose to reduce air turbulence while increasing air volume and air speed delivered to the turbo. The Revo hose’s four-ply construction, coupled with an internal wire helix, increases strength to prevent collapsing under high vacuum and engine bay temperatures. The Revo flush fit internal steps create a smooth transition between the aluminium intake pipe and Revo turbo inlet, to ensure the smoothest airflow possible within the system.
The Revo machined inlet replaces the restrictive elbow found on the low output vehicles fitted with the transverse 2.0T EA888 Evo engine variants. The anodized aluminium inlet, machined from a single billet, fits securely into the OE compressor housing using locking tabs and an integrated O-ring. The internal bell mouth structure of the upgraded inlet perfectly complements the increased size of the Revo hose, as the Revo inlet’s bell mouth allows for a smooth airflow transition from a large cross-sectional area (at the end of the Revo hose) to a smaller one (at the turbo compressor wheel inlet), within a small physical space. This transition allows the intake air to stabilise when entering the turbo, tappering air-volume and reducing turbulence within the inlet. The Revo part further removes any unnecessary turbulence through strict machining tolerances and QC, ensuring a perfect flow-match with the OE compressor housing and uninterrupted, highly laminar airflow into the turbo for maximum intake performance.
An intake system is only as good as the filter. The Revo open cone kit comes complete with a custom Revo three-stage foam filter, supported by galvanised epoxy-coated mesh for foam support under extreme vacuum load. Revo three-stage foam filters work very differently from conventional paper or cotton-gauze alternatives, designed to trap large particles on the outer layer and progressively finer particles on the inner layers. This triple-mesh design allows for equal-or-better levels of air filtration compared to the OE filter, while still allowing significantly higher volumes of filtered air into the Revo intake system. The Revo-designed and custom-manufactured rubber filter base features a radius feed into the Revo aluminium pipe work, as well as a Revo Flush Fit connection to the pipe work to maximize filtered air volume and stability into the Revo kit.
Ensuring the engine has access to cold air is vital for performance. The Revo heat shield was designed utilising the latest in 3D scanning technology to create a closed, fully welded shield that effectively insulates the Revo filter from radiant engine bay heat on all sides. Further utilising the 3D scanning technology, the Revo heat shield features a precision-designed provision for the front air duct to channel cold, fresh air directly to the filter as well as fixturing to the OE mounting points, with OE mounting grommets, providing unparalleled functionality, fitment and ease of installation.
RESEARCH AND DEVELOPMENT
All Revo products are designed in-house and are designed utilising an in-house 3D printer and 3D scanner, as well as the latest CAD and CFD programs. Airflow testing was carried out on both the full OE intake system and the Revo open cone kit at a third party, independent facility in a controlled environment to ensure fair test data was captured to quantify how much restriction the Revo intake kit removes from the EA888 Evo low output intake system.
The bench flow testing results show improvement throughout the entire flow range, but especially towards the top end of the flow testing range, showing how the OE system severely restricts engine performance at higher air flow volumes. The Revo open cone intake was able to flow over 650 CFM at a 914.03 mmWg restriction, over 50 CFM more than the OE system (which maxed out at approximately 600 CFM flow at a significantly higher 1126.73 mmWg restriction). At the OE maximum flow value of 600 CFM, the Revo kit showed an improvement of 369.91 mmWg less restriction (a 48.88% reduction) - as can be seen on the graph. The 369.91 mmWg reduction in airflow restriction at 600 CFM (as well as the maximum restriction reduction of 78.4% at 350 CFM) clearly demonstrates how the Revo intake kit out-performs the OE system throughout the airflow range, highlighting the improvements in airflow and overall increase in engine power gains with the Revo open cone kit.