Tiguan S3 Intercooler Install Guide

[tigger73]

Definitely you should be getting significant gains considering intercooler was being the bottleneck in your system. I think boost drop through your old intercooler is very high considering high flow rates involve in Stage 2 tune. So there is your missing 20 hp you were complaining right there.

Yes I thought I was down around 15kwaw to where I thought I should be and it was all down to the intercooler causing a big restriction in the system. Will be really interested to get it back on the dyno. Should be 150+kwaw now.



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[brad]

I guess if you've done intake & DP/exhaust then yes the 32mm IC will be a killer. I still can't see how going from 38mm plastic to 40mm alloy would make a huge difference but your logs prove me wrong so happy days.

Have you changed the IC charge/discharge pipes to the round units yet?

0-100 relies too much on reflexes & ability to change gear quickly (you guys probably have auto & launch control so maybe not).

When I did the stage1 Bluefin on the Octy I just did in-gear rolling runs as it took the driver & gear changes out of the equation & doesn't stress the car as much with clutch dumps & quick changes.

I should do this again soon before I fit the IC to see what difference the charge/discharge pipes; intake mod & DP mod have made.

40-120 in 3rd gear. 40kmh is just off boost at just on 1500rpm (didn't really look).
Before: 10.99 / 10.92 / 10.96 - call it 10.95?
After : 8.82 / 8.80(det)/ 9.02 - call it 8.95?
~2 seconds/ 18% reduction

40-140 in 4th gear. 40kmh is way off boost at about 1000rpm
Before: 14.99 / 14.74
After : 13.79 / 13.48 / 13.72
Call it 1 second better? 6% improvement?

Then as an afterthought (and because the pull was so bloody addictive) we did an 80-120 run in 3rd. Sweet Jesus, Mary & Joseph!!!
4.83/4.32/4.26
/searches - dumb comparison but an M5 does 80-120 in 4th in 4.8seconds
Wheels 3rd gear times - Porsche Boxter S = 4.7s; Mazda RX8 = 4.6s; 350Z = 4.1s; Mazda 6 MPS = 3.6s
So around 4.5s seems quite respectable for a near 1.5tonne, 1.8L shopping trolley.

[Ramee]

I guess if you've done intake & DP/exhaust then yes the 32mm IC will be a killer. I still can't see how going from 38mm plastic to 40mm alloy would make a huge difference but your logs prove me wrong so happy days.

Have you changed the IC charge/discharge pipes to the round units yet?

Haha! Everybody knows those round pipes and stock ones have almost same cross section area. So no point of spending money for nothing I only will consider IC discharge pipe if I ever install water Meth kit as it is pre drilled for WM nozzles.

[brad]

Haha! Everybody knows those round pipes and stock ones have almost same cross section area. So no point of spending money for nothing I only will consider IC discharge pipe if I ever install water Meth kit as it is pre drilled for WM nozzles.

Actually, they haven't got "almopst the same x-sectional area". Mine are about 10% bigger when measured at the largest point. The difference is much greater when measured at the smallest x-section. The pancake pipe is worst for this as the x-section is all over the shop. Mine also removed a restriction between the turbo & the pancake pipe.

None of these smaller mods make huge differences in isolation but as a sum-of-the-parts equation it all starts to add up with regards to either power or driveability.

[tigger73]

Tiguan S3 Intercooler Install Guide

Found this post while digging up stuff for the intercooler installation guide:

Our engine codes that we have worked on so far are:

CAWA = 125kw
CAWB = 147kw

It looks like the intercooler is different (and some of the plumbing) & the rear exhaust is also different, looks like the intake is the same & most base parts are the same though!

So as suspected the 125 and 147TSI do have different intercoolers and means that upgrading intercoolers on a 125TSI is going to provide a greater benefit - which is also what I have discovered. This benefit is going to be even more pronounced at stage 2 and release those kW being sucked out by an overly restrictive intercooler.

[nat225]

So the extra few thousands $ for 147TSI actually bought bigger FMIC pipes!

I always thought the folding tables behind the front seats, some different 1010101 codes in the ECU tune and shinny silver trims make up that $$$$ difference! Lol

Good to know that

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[Transporter]

So the extra few thousands $ for 147TSI actually bought bigger FMIC pipes!

I always thought the folding tables behind the front seats, some different 1010101 codes in the ECU tune and shinny silver trims make up that $$$$ difference! Lol

Good to know that

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I'm sure that the 147Tig is worth more than 125Tig in the used car market as well.

...and it doesn't matter how much extra money you push into the 125Tig, it still will be the 125Tig.

[tigger73]

Tiguan S3 Intercooler Install Guide

So the extra few thousands $ for 147TSI actually bought bigger FMIC pipes!

I always thought the folding tables behind the front seats, some different 1010101 codes in the ECU tune and shinny silver trims make up that $$$$ difference! Lol

Good to know that

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The 147 will have a thicker core -suspect it may be similar to the one on Ramees 155 which has a 38mm core instead of the 32mm one on the 125.

So the 147/155 will actually make more power once tuned... until you upgrade the intercooler on the 125/132tsi.

...and from memory the folding tray tables only came with leather option and wasn't a feature on the 147 as standard.


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[Wynnston]

The 147 will have a thicker core -suspect it may be similar to the one on Ramees 155 which has a 38mm core instead of the 32mm one on the 125.

So the 147/155 will actually make more power once tuned... until you upgrade the intercooler on the 125/132tsi.

...and from memory the folding tray tables only came with leather option and wasn't a feature on the 147 as standard.


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It's totally all in that "Driver Fatigue Warning System".

[Tiggy1]

That is interesting. I'm wondering if it's because yours is a 155TSI and mine is a 125TSI that I got the smaller intercooler. I suspect this may be the case that the 147/155TSI get the upgraded intercooler to cope with the extra power. Just means that there's more to be gained for a 125/132TSI upgrading their intercooler than someone with a 147/155TSI.

I'll be interested to see what the dyno shows when I get back on there. If the intercooler was causing a pressure drop/turbo to work harder I should (hopefully) get better flows/more boost and theoretically more powa

Nope,
Just checked my MY11 147TSi and it's the same part number and thickness as your 125TSi!
Looks like I'll be on the the lookout for an S3 intercooler as well....
While under there I fitted up GFB DV+ like Ramee got - no noticeable diffrence (not that I was expecting it) but probly for the best anyway as discovered it had the old style diaphragm type DV so probly only matter of time before it failed?!

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[Tiggy1]

Actually, they haven't got "almopst the same x-sectional area". Mine are about 10% bigger when measured at the largest point. The difference is much greater when measured at the smallest x-section. The pancake pipe is worst for this as the x-section is all over the shop. Mine also removed a restriction between the turbo & the pancake pipe.

None of these smaller mods make huge differences in isolation but as a sum-of-the-parts equation it all starts to add up with regards to either power or driveability.

Hi Brad,
See what you mean by the restriction in the pipes (plastic ones that run beside engine) - definitely got that squished look!
Presume the S3 ones are the ones you're talking about that are "rounder"?
If so, would you know part numbers and if they'd be direct replacement (with S3 intercooler and hoses at same time)?
My only other concern is that where it runs past the "front" ( ie. RH side) of engine there could be a clearance problem with the crank pulley/dampener?!

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[tigger73]

Nope,
Just checked my MY11 147TSi and it's the same part number and thickness as your 125TSi!
Looks like I'll be on the the lookout for an S3 intercooler as well....
While under there I fitted up GFB DV+ like Ramee got - no noticeable diffrence (not that I was expecting it) but probly for the best anyway as discovered it had the old style diaphragm type DV so probly only matter of time before it failed?!

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Well I stand to be corrected. They've cheaped out on the 147 intercooler as well.

Would be interested if someone with a 132TSI can check to see if they have the larger or smaller width core.

I guess that means anyone with one of the first gen Tigs has some decent gains to be made from upgrading intercoolers.

Hi Brad,
See what you mean by the restriction in the pipes (plastic ones that run beside engine) - definitely got that squished look!
Presume the S3 ones are the ones you're talking about that are "rounder"?
If so, would you know part numbers and if they'd be direct replacement (with S3 intercooler and hoses at same time)?
My only other concern is that where it runs past the "front" ( ie. RH side) of engine there could be a clearance problem with the crank pulley/dampener?!

From the reviews I've seen looks like there's an AWE one and a Nuespeed and the Nuespeed seems to have better reviews in terms of fitment and not leaking.

[tigger73]

Looking at options for turbo outlet pipe and air charge pipe also.

Seems that Nuespeed is a top quality product but will be $500-$600 landed for both parts:

HI-FLO Turbo Discharge Conversion - TSI
HI-FLO Air Charge Pipe - Eliminates OE Sound Amplifer

Also available from speedlife (as recommended by Lucas_R):

NEUSPEED HI-FLO Turbo Discharge Conversion - TSI 48.02.71
NEUSPEED HI-FLO Air Charge Pipe - Eliminates OE Sound Amplifer 48.02.68 - Speedlife Motorsport

There's also some no-name ones available off ebay which may be worth a try: Aspec VW Audi 2 0 TSI HI Flow AIR Charge Pipe Turbo Discharge Conversion Black | eBay

[Lucas_R]

Tiguan S3 Intercooler Install Guide

Also look at the Spulen version from USP Motorsports. They look good - ill probably get the Spulens for the GTI soon. http://www.audizine.com/forum/showth...pe-*Group-Buy*

If you decide to get the NeuSpeeds, then Speedlife is the place (good service and good shipping prices).

[Tiggy1]

Hmmm,
The Neuspeed one is obviously better design as it removes the restriction at the end connector as well, but there is quite a big price difference. I think intercooler will be first priority then will consider this some more

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