Intercooler change DIY

[NOO63N]

That's true. Is there anything else worth changing in 1 go as I do the job? I'll be also running the wiring of my OPS kit I've had lying around for almost 2 years as well as fixing my front bumper.

On an unrelated note, how would I go about doing a turbo health check. My mechanic sometime ago said there was some oil coming from there, nothing major, reckoned it was a seal or gasket...

[zei20t]

turbo is on the back of the engine. get it on a hoist, makes it a billion times easier.

[NOO63N]

Yeah might do that next time at my mechanics. Other thing I was considering was taking off the air intake pipes and seeing if there was any movement on the shaft...

[Lucas_R]

Yeah might do that next time at my mechanics. Other thing I was considering was taking off the air intake pipes and seeing if there was any movement on the shaft...

You cant get to the turbo shaft by removing the intake (the turbo intake has a 90 degree bend) so if you want to check for shaft play you will have to remove the dump pipe and then you can reach the exhaust wheel of the turbo.

[NOO63N]

You cant get to the turbo shaft by removing the intake (the turbo intake has a 90 degree bend) so if you want to check for shaft play you will have to remove the dump pipe and then you can reach the exhaust wheel of the turbo.

Hi Lucas, is it necessary to remove the downpipe or can I do it from the top where the intake connects? I've got a new downpipe ready for fitting, just not confident in having the tools to do so, may leave it to the professionals to save frustration and hours upon hours of swearing haha

[Lucas_R]

Hi Lucas, is it necessary to remove the downpipe or can I do it from the top where the intake connects? I've got a new downpipe ready for fitting, just not confident in having the tools to do so, may leave it to the professionals to save frustration and hours upon hours of swearing haha

No you cant get to it from the top - there is a 90 degree bend made of aluminium coming of the turbo inlet that restricts your access.

Downpipe is not hard on a FWD - i put a downpipe on my Mk6 GTI a few months ago. All you need is a socket set (18mm from memory) with some extensions, a ratchet spanner (18mm from memory) is very handy but you can make do with a normal spanner, and an adjustable spanner to get the o2 sensors off.

[NOO63N]

I might take a long, I was inclined to go to an exhaust shop knowing that there will need to modifications performed on the downpipe to compensate for length...

The intercooler job I will try on my own...lol

Being a budget build, this is the budget golf r intercooler and downpipe I picked up for a good price.









Do you guys think this jetta cat back exhaust would work on a petrol 1.8tsi?

http://pages.ebay.com/motors/link/?nav=item.view&id=301011458588&alt=web

[brad]

Hi Lucas, is it necessary to remove the downpipe or can I do it from the top where the intake connects? I've got a new downpipe ready for fitting, just not confident in having the tools to do so, may leave it to the professionals to save frustration and hours upon hours of swearing haha

If you are capable of doing the IC then the downpipe should be a doddle.

edit: hadn't seen the pictures. You'll need an exhaust place because the OEM connection is a butt fit with a sleeve clamp & your DP is an (I call them) oyster clamp joint.

Does your downpipe have 2x elongated holes on it as the Golf R has a slightly different stud layout than the TSI

Link doesn't work for me (probably my PC).

[NOO63N]

Not sure if this will help, but this is what it started out as:



Not sure what you mean by the differences sorry, could you clarify with pictures perhaps?

And this is the eBay cat back, for a diesel but should work for a petrol being just pipes essentially. Will probably be very loud being a straight pipe I imagine but would be a long the same lines as an ark designs exhaust for the gtis.

[brad]

All the components tell a better story. If you've got the length to the OEM catback right it will be fine. It will take you about 1.5-2hrs to do a test fit at home. It will either be right or wrong. Have a crack

This flange fits Golf R & TSI turbos. Note the top holes have been elongated

[NOO63N]

Hmm...

Just looking at this thread:
Mk2 Octavia Tfsi Pipewerx decat downpipe brand new - Car Parts For Sale - BRISKODA.net - The Skoda Forum and Community

Flange looks different?

[brad]

just cut different & different camera angles I would think.

The two flanges are interchangeable as long as the holes are elongated. If your holes need elongating you can do it with a round file & some effort. I have heard of people drilling them but I think that would be more trouble than the effort was worth as you'd be trying to drill half a hole & the drill would run off centre. You could drill some small holes just to remove some material before filing but again, probably just easier to hook-in & do it

[NOO63N]

just cut different & different camera angles I would think.

The two flanges are interchangeable as long as the holes are elongated. If your holes need elongating you can do it with a round file & some effort. I have heard of people drilling them but I think that would be more trouble than the effort was worth as you'd be trying to drill half a hole & the drill would run off centre. You could drill some small holes just to remove some material before filing but again, probably just easier to hook-in & do it

Thanks Brad! My next question is whether or not anyone can recommend an exhaust place to carry out the work for a reasonable amount. I've called locally to me from Liverpool to Bankstown to Northmead, the places I've called said they weren't familiar with Skoda or VWs but would give them a shot at $100/hr.

I guess I'm somewhat reluctant to pay someone $100/hr to learn about a Skoda or VW.

Happy to support the local guy if you have suggestions.

[brad]

Thanks Brad! My next question is whether or not anyone can recommend an exhaust place to carry out the work for a reasonable amount. I've called locally to me from Liverpool to Bankstown to Northmead, the places I've called said they weren't familiar with Skoda or VWs but would give them a shot at $100/hr.

I guess I'm somewhat reluctant to pay someone $100/hr to learn about a Skoda or VW.

Happy to support the local guy if you have suggestions.

Liverpool Exhaust usually gets a reasonable review.

Otherwise ring Seb at Giraween or Ramspeed or one of the other independant VW guys & ask them who they use.

The job you want done isn't difficult

[zei20t]

IMO, new flange is the only way. use the factory gasket as a template and have a new flange laser cut - like I did - then have the new flange welded on in the SAME position as the one you have cut off. simples.

there is too much heat and expansion/contraction to elongate a hole and leave insufficient material to support something so important.