Intercooler change DIY

[Mysticality]

Post 12

Your's is the same as mine. Even a GolfR intercooler would be an improvement. Cheap too.... until you add $200 worth of extra pipes

Pipes? Where for?
The outlets on the aftermarket intercoolers appear to be exactly the same as the 32mm one

[brad]

The extra pipes & hoses I bought in the photo earlier. They aren't necessary but I figured what I saved on the IC I may as well spend on either side of the IC.

[MountainBikeMike]

That's good to hear, Mike. I was a little worried, but with the price I can easily move it on if its not suitable for my car.

darkshadow, yes ill be installing myself, if I can get the workshop this weekend ill have a hoist, but I might end up in my garage.

How did you go?

[zei20t]

OK install was a bust

I removed the whole front end, got the old cooler out and had the new one sitting in place. the adaptor from the factory piping to the supplied silicon hose didn't fit the hose.

ill have to speak to the selling about supplying the correct part!

6 hours of my life wasted. I did the whole process logically, got the car back together with no issues, no bolts, nuts or screws left over. nothing is loose. one minor problem, the tray holding a headlight is a little high, had to adjust one of the headlights.

[brad]

When you do it the 2nd time, if you think the job would be quicker / easier with 2 people we should try & get together. I'll help you do your IC & you can help me with mine.

[MountainBikeMike]

Ah shiz. If you make contact with kinz-import can you see if they'll organise one for mwa as well? Or get a part number?

[zei20t]

When you do it the 2nd time, if you think the job would be quicker / easier with 2 people we should try & get together. I'll help you do your IC & you can help me with mine.

wouldn't mind a hand at all, and happy to help in return. I know how much I have to take off, and when etc.

can probably get two done in a day! it was damn hot Saturday, and I stopped to do some VCDS coding also. forgot that was part of the 6 hrs. he paid me in beer, which was well and truly earned after that day haha

[zei20t]

Ah shiz. If you make contact with kinz-import can you see if they'll organise one for mwa as well? Or get a part number?

ill see what I can do, they may not send two, you may need to make contact also.

its also entirely possible I was sent a wrong part. it happens.

[brad]

wouldn't mind a hand at all, and happy to help in return. I know how much I have to take off, and when etc.

can probably get two done in a day! it was damn hot Saturday, and I stopped to do some VCDS coding also. forgot that was part of the 6 hrs. he paid me in beer, which was well and truly earned after that day haha

Have you got your hoses sorted yet?

Yell out when you are ready to do the job.

[Lucas_R]

I removed the whole front end, got the old cooler out and had the new one sitting in place. the adaptor from the factory piping to the supplied silicon hose didn't fit the hose.

ill have to speak to the selling about supplying the correct part!

Ahh bugger. How frustrating.

There's a place in the UK who sell the VW/Audi/Skoda alloy bung adapters in various sizes. Let me find the ebay link to the item and ill get back to you. you just need to measure your pipes and order the correct size (there's about 6 sizes to choose from).

EDIT: Here is the shop in the UK: http://www.creationsmotorsport.com/p...main=3&catID=6 (look about half way down this page.)

They also advertise on ebay too if you do a search. I bought one from them (via ebay) about a year ago but i got the wrong size by mistake (too small).

EDIT: Here is the ebay page: http://www.ebay.com.au/itm/VW-AUDI-S...-/150802992992

[brad]

I thought about blowing off the end tanks but I can't envisage that being an issue for me.

I believe the plastic tanks flow better as it's easier to plastic mould curves, etc. I've seen enough metal casting to know that you can almost anything with metal - maybe it's just the fact that plastic is cheaper.

As part of this "fine tuning" exercise I just bought this on ebay.
[ATTACH=CONFIG]7216[/ATTACH]

Had some quality time under the Octavia this weekend. Finally got around to fitting the new intercooler pipes - still haven't fitted the intercooler.

The process was relatively trouble free. Surprisingly, the pipe fron the turbo to the IC was easier than the IC to TB pipe. Partly because somebody had overtightened the screw on the bracket so I had to butcher it off.

All the hoses were the right length & the angles of the locating dimples were correct. A perfect fit for a TSI engine.

The old pipes & hoses were quite oil misted & about 20ml of black goop came out of the IC to TB hose when I disconnected it.

The connection from the turbo to the pipe is about 5mm bigger. The turbo-IC pipe itself is a bit over 10% bigger in x-section than the biggest point on the old pipe.

I haven't road tested it yet. Just finished & having lunch.

Photos & thoughts later

[zei20t]

it probably only makes a difference on the top end. however, I did too many mods at the same time, so I cant tell you how much of a difference it made

[brad]

Did some more work in this part of the engine over the weekend.

Removed the downpipe & took out a restriction that VW had put directly next to the turbo outlet.
Positives: turbo spools a fraction quicker & at slightly lower rpm. It's nothing significant but it is better.
Negatives: Engine makes more noise at cold start idle. It goes away within 400m of driving or if the rpm is increased slightly.

Decided to fit the new turbo to intercooler pipe & IC to inlet manifold pipe that I bought in January.


I was somewhat dubious that these would fit as plenty of others have experienced issues with size, bracket location & general build quality. I must be lucky because none of this appears to have been an issue. I did have a slight problem with fitting the sensor - new bolts required & the holes were maybe 0.25mm out of line which was enough to kink the bolt slightly.

I did the pipe from the Intercooler to the Inlet manifold first (RH pipe & the 45degree elbow in the photo). Removal of the old pipe would have been straight forward but some mutton-head had done the mount bolt up too tight & I had to butcher it out which added 30 minutes to the process. About 20ml of black, viscous oil dribbled out of the hose when I disconnected it & in generally the pipes & hoses were coated in oily gunk. The throttlebody appeared pretty clean though.
Old pipe from IC to Inlet - you can see it's kind of squashed & fat - maybe 40mm x 80mm = 2400sq mm x-section. The new pipe is 60mm = 2828sq mm



New pipe



Old Pipe Turbo to IC. A fraction smaller & still squashed & fat. X-section increase was about 10% & the "hole" from the turbo to the pipe went from about 45mm to 55mm



New Pipe

[zei20t]

Nice work! I did the exact same things several months ago. also didn't have problems with the pipes, except the sensor spot.

I think it makes a difference on the top end, having the flow of air much cleaner. but only a dyno will prove results.

[brad]

Have you done your IC yet or are you still trying to sort out the hoses?