Intercooler unecessary, the stock one does a stellar job for a normal road car, I've tested mine extensively. The single biggest source of heat in the inlet ( after the turbo compression ) is the EGR, so getting an EGR blanking plate and drilling a 10mm hole in it to stop the error light from showing up, cuts down the problem dramatically, and for about $5 plus post from ebay UK. Single best idea for a TDI in my opinion for dropping soot, reducing crud buildup and assisting power production. Oh and get a catchcan - Provent is the go.
Then tune it up, the torque increase alone from a decent "chip" in a diesel is amazing!
Then tune it up, the torque increase alone from a decent "chip" in a diesel is amazing!
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