intercooler...

Post by **airhead** » 30 Aug 2007, 18:23

I got myself a nice little 2 core intercooler off a Golf TDI in a scrapyard. €70 is all it cost me and I got it when I was getting the seatbelts for the back of the van, another annoying job I got out of the way today. Anyway, I need some advice. I was looking intently at my engine bay for a while with the intercooler in my hand trying different places for it. In the end I decided the best thing in fact is to put it where the air filter and turbo cooling fan is. This puts it away from the hot exhaust and turbo and in a good line of fresh air. The questions are, will I need to fit a fan? The intercooler I got has a thermostat on it so its handy that way. What can I do with the air filter? I was thinking Id need a new smaller one and I could put it behind the battery in the other air vent, and just run a pipe over there to it. What other things do I need to know? Im going to be doing a lot of this job myself with the help of a welder friend of mine (the guy who welded in the seatbelt mounting points today). Ill be getting custom pipework made. Any other suggestions?

Post by **HirMiller** » 30 Aug 2007, 18:41

I have looked into this as well, and what you are proposing is the way all the pros do this job.

Post by **Ziegel** » 31 Aug 2007, 10:38

You've probably seen this, but if not there's some pics of an installation here: http://www.syncro-bernd-jaeger.de/ENGLI ... er-td.html

Post by **toomanytoys** » 31 Aug 2007, 11:36

Keep it simple and pull the air intake from a clean cool area.. you could mount it so the intake is abouve and then direct air over the intercooler from the air duct..
Another location is next to the gearbox and duct the air through it.. but needs protecting from road debris..

Post by **PEET** » 31 Aug 2007, 16:54

Mines ABOVE the gearbox but is 90 degrees out i.e away from any airflow (some german muppet fitted it not me?!) I'm rotating it and making a ducting from flexible plastic see how that works!

Post by **airhead** » 31 Aug 2007, 17:41

Ziegel wrote:You've probably seen this, but if not there's some pics of an installation here: http://www.syncro-bernd-jaeger.de/ENGLI ... er-td.html

Yeah I had a look at that before. Thats really what i had in mind, only I will use rubber pipes instead of metal cause I cant afford to get metal pipes made. Ill get a whacking big fan for it as well. I dont understand how Bernd Jaeger is charging €1950 for the job though! Seems a bit steep really. Im mean its not the most complicated thing in the world.

So about the air filter, whats the story there? can it stay where it is if I just move the intake pipe to the other side or does the whole lot need to be moved?