XS –POWER – SSAUTOCHROMEFull size intercooler on a TDI 200/300

The Standard Intercooler In Mounted On The Left Side Of The Radiator (Driver's Side In A Left Hand Drive Vehicle),

Its A Small Radiator That Cools The Air That Flow Via The Turbo To The Engine.

The Cooler The Air Is, The More Oxygen Molecules It Has, Hence It Will Burn Better.

Replacing The Original Intercooler With A Full Size One (That Is Almost Triple Its Size) Will Enrich

Mixture Of Fuel And Air That Goes Into The Cylinders.

Studies Show You Can Gain Up To 25% In Engine Performance,Especially In Torque (Moment) ,

Phase 1 - Removing the old unit

·  remove the plastic grill.

·  remove the top panel (above the radiator) with the bonnet lock and the 2 bars.

·  remove the front panel.

·  remove the bolts of the plastic fan cowl.

·  remove the intercooler's hoses.

·  on the intercooler's bottom side their are two brackets that fit into supports in the chassis,save the rubber bushes

on the brackets for later use.

·  gently pull it up and your done.

-- Dismounting the old intercooler--

Phase 2 - Building the mounting

According To Different Forums You Can Fit The New Intercooler's Brackets To Fit Into The Chassis Support Previously Used

By The Supporting Bar,You Will Need To Cut If The Bottom Edge Of The Front Panel For That.

If You Have Such Support You Can Skip This Phase.

You Can Either Weld The New Mount To The Chassis Or Connect It With Screws.

new bracket dimensions:

length- 77 cm

wide- 4 cm

height- 2 cm

distance between the 2 mounting holes - 64 cm

Diagram:


-- Making the new mount--

-- new mount in place --

Phase 3 - Fitting the new Intercooler

·  place the rubber bushing in the new mount.

·  place the new intercooler in its new location,insert from up to down,push gently until its in place.

·  you Will see that the intercooler pipes are longer that the original one's and that the radiator cowl needs to be modified in order to make Clarence for the intecooler pipes.
use a hot knife to cut the plastic so the pipes fit in.

·  its a good thing to use this opportunity to replace the old intercooler hoses, new silicone ones are preferred,you will have to adjust the hoses a little to fit the new intercooler, i needed to move the intake hoses a little (the metal one that is attached to the driver's side wing).


-- Setting the new intercooler in place --

Phase 4 - closing

·  TIGHTEN THE INTERCOOLER'S BANDS.

·  FIT IN THE FRONT PANEL

·  FIT IN THE TOP PANEL

·  REFIT THE FRONT GRILL

-- final result --

Conclusions

The whole process took around 5 hours,if you wont need to build the new mount then even much less.

feel the power improvement in the Engine's mid range, the torque (moment) is better.


THANKS AND PROPS TO !