IE has worked with Mahle for several years now developing leading performing pistons offering industry-leading features. These custom spec pistons are engineered for your VW/Audi 2008+ 2.0T TSI high-performance engine build offering unmatched strength and longevity when coupled with IE connecting rods.
These pistons are engineered with compression ratios very close to the factory 2.0T TSI (EA888 Gen 1,2, &3) compression ratios. We have tested these engines with several other compression ratios, both lower and higher and found that they are very susceptible to knocking, due to the complexity and precision of the direct injection system. The compression ratio varies depending on the 2.0T TSI engine generation.
Compression ratio by engine:
IE Spec Mahle Pistons are available in two bore sizes to suit your build. 82.5mm (stock bore size), when paired with a set of our rods, are ready to drop in and run in your engine without the need to remove the block. We also offer them with +.5mm overbore (83mm bore), which increases displacement to 2008cc and allows you to bore and hone the block to the exact specifications required to ensure best results. We recommend overbore pistons on most builds (unless the engine has very low miles) to ensure a perfect piston to cylinder fit and long-life operation.
These piston sets include high-quality 22mm diameter German steel wrist pins and wire locks. Strenuous testing of multiple pin sizes on this piston and engine combination has determined the 22mm pin is ideal for weight, strength, and durability. To match these pistons, a 2.0T TSI specific connecting rod with a non-tapered 22mm small-end is required. IE offers multiple industry-leading performance connecting rod options that are a direct fit and perfect match for your 2.0T TSI bottom-end build.
The only way to make an aftermarket performance piston operate like an OEM piston is to design it like one. These pistons are designed with a proprietary factory-style dish on the crown, which is absolutely necessary for smooth operation with the direct injection system. If this shape of dish is not used, combustion is poor and engines do not run smoothly. In order to call these pistons the ultimate replacements for OEM, they need to fit like them. They are made with the same oil squirter notches found on factory pistons. These Pistons do not require any modifications for squirter clearance or fitment.
To maintain OEM-like wear characteristics, these pistons are coated with Mahle’s Grafal skirt coating. This coating reduces friction on the skirts, keeping them quiet and from wearing over time- extending piston life. The grey appearance of these pistons is due to a phosphate coating. Providing a lubricant film in the pin bores and ring grooves, this coating is essential for initial startup and break-in of the engine to prevent micro-welding and galling. Features like these are what allow these pistons to last for thousands of miles, just like OEM units.
These pistons are manufactured from Mahle’s proprietary 142P alloy. This unique alloy offers the low-expansion characteristics of 4032 but strength near that of 2618 alloy. The low-expansion quality allows piston-to-wall clearances to be set tight, which allow the pistons to operate like OEM, quietly and smoothly.
Included is a set of performance piston rings, featuring a barrel-faced top ring, ductile iron, and 3 piece oil ring. These rings are designed to eliminate unnecessary drag, which reduces friction and increases power. To maximize power output, the clearances between the rings and piston have been brought in very tightly to reduce blow by. This is achieved by hard anodizing the top ring lands, which prevents micro welding which could be caused otherwise. Beneath the top ring and second ring lands an accumulator groove is machined, which provides a cavity where blow-by gasses can collect. This reduces pressure between rings, while virtually eliminating ring flutter and keeps top rings sealed securely against the bores.