GT63 Billet intake manifolds (X290)
MANIFOLD CONSTRUCTION The factory manifolds are constructed from plastic, in 2 halves and then plastic...
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ECU Reflash required? NO
MANIFOLD CONSTRUCTION
The factory manifolds are constructed from plastic, in 2 halves and then plastic welded (melted) together) This construction method is economical for large scale production, and (mostly) ok for standard engine power. However, the limits of the factory manifolds are well documented...
Furthermore, the plastic is not able to be drilled or tapped, so optional ports for nitrous, meth, or boost sense cannot be added. Finally, there is no way to add extra port injectors to the plastic manifolds, limiting fueling options.
ZAC Motorsport engineers researched several construction methods:
1) Casting
+ cheaper to produce
+ able to be produced as a single piece
- Inferior strength (material selection, porosity, hot spots)
- questionable finish
- low accuracy
- requires post processing (machining)
2) 3D Printed metal
+ able to be produced as a single piece
+ great surface finish
- expensive to produce
- slow construction process
- limited production facilities worldwide
- requires post processing (machining)
Billet Machining
+ extremely strong material
+ great surface finish
- requires 2 piece construction
+ relatively common manufacturing process
+ extremely accurate
We settled on machining billet 6061-t6 aluminum. Whilst casting would have saved us costs (1/3rd the cost to produce). The quality of the end product does not meet our standard. Additionally, machining allows us the ability to make incremental changes, or small batch runs with specific customizations (different size port injectors for example), whereas casting requires an investment of a mold, that cannot be changed. All manifolds from ZAC Motorsport are machined therefor, then TIG welded, by our master craftsman right here in Australia.
Optional Port Injection
As emissions regulations get tighter and tighter, manufacturers have had to develop technology to meet the stringent emissions targets. Direct injection (DI) is one of the results. With Mercedes opting for pure DI setup, as opposed to VW group using a combination of port and DI. Our port injection option retrofits to offer similar flexibility and tuning options (when coupled with a Piggyback ECU) as the VW/Audi systems.
The benefits of Port Injection:
- Increased fuel capacity
- Port cleaning effects of fuel into the intake runners, reducing carbon buildup in the ports and on the back of the inlet valves.
- IAT cooling into the combustion chamber
- Ability to run full E85 fuel.
WARRANTY:
Warranty
We stand behind every product we make. Our warranty reflects the confidence we have in our design and engineering. If you have any issues, please don't hesitate to reach out — sales@zacmotorsport.com
Warranty Coverage
ZAC Motorsport products are warranted against defects in materials and workmanship for the original purchaser from the date of purchase. Coverage periods vary by product type:
Covers defects in materials and workmanship across our standard product range including intakes, downpipes, exhausts, intercoolers, and engine bay components.
Limited warranty valid from date of receipt. These products have a shorter warranty period due to the nature of their intended use and performance application.
Satisfaction guarantee from date of purchase. If you are not satisfied with your tune within 30 days, contact us and we will work to resolve it.
Custom and made-to-order products, forged wheels, and brake components are not covered under warranty.
What's Not Covered
This warranty does not cover:
- Shipping costs of any kind
- Damage due to transportation or incorrect storage
- Vehicle downtime, rental vehicle, or towing costs
- Labor costs to diagnose or replace ZAC Motorsport products
- Normal wear and tear, including loss of shine, scratching, or yellowing of carbon fibre products
- Damage caused by accidents, abuse, poor maintenance, or neglect
- Modifications made to any ZAC Motorsport product without prior consent
- Replacement or service items such as filter elements and clutches
- Damage caused by acts of God or external causes beyond normal use
Warranty Exclusions — Misuse
The following will void your ZAC Motorsport warranty:
- Installation by an unqualified or unapproved installer
- Any disassembly or attempted disassembly of a ZAC Motorsport product
- Failure to install required supporting modifications
- Restricted or blocked turbocharger air intake
- Lack of adequate oil or fluid supply to the product
- Failure to use coolant/antifreeze in intercooling or heat exchanger systems
- Use of poor quality fuel or failure of the fuel system
- Improper maintenance or fluid levels
- Abusive use including riding the rev limiter or excessive burnouts
- Any form of racing or off-road use
- Use of non-ZAC Motorsport ECU and/or TCU/CPC calibrations
- Ingestion of foreign debris
How We Resolve Warranty Claims
If your product is confirmed defective under warranty, we will repair it at no charge. If repair is not possible, we will replace it with a product of similar composition, or at our sole discretion, refund the full purchase price excluding freight costs — only once the product has been returned and inspected. There is no charge for inspection. Return freight is the responsibility of the customer.
How to Make a Warranty Claim
Email us at sales@zacmotorsport.com with the following:
- Your order number
- A description of the issue
- Clear photos showing the defect
We typically respond within 1 business day, Monday – Friday, 8:00am – 5:00pm EST. We'll work with you to find the best resolution as quickly as possible.
Emissions Compliance
Some ZAC Motorsport products are designed for performance use and may not comply with emissions regulations in all regions. It is the customer's responsibility to verify local emissions laws and ensure compliance before installation. ZAC Motorsport cannot be held responsible for any non-compliance in emissions testing.
Limitation of Liability
Disputes & Chargebacks
We are committed to resolving any issues fairly and promptly. If you have a concern with your order or product, we ask that you contact us directly at sales@zacmotorsport.com before initiating a dispute or chargeback with your payment provider. In most cases we can resolve issues quickly without the need for third-party intervention.
Customers who initiate chargebacks without first attempting resolution through our support team may have their warranty voided, their account suspended, and future orders declined.
Included in the box: