Twin inter cooler set up

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bradh

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Guys just thinking out load hear but has any one fitted the twin inter cooler set up off the v6 tdi onto a 1.9tdi version

Any gains to be had ??
Is it possible
If so what's needed to do it??
 
So im not mental then it's not just me that's thought about it , looking at cars breaking on eBay just looks like a drivers side cooler and couple of pipes plus mounting for cooler would be needed
 
One may need to tweak a hose or make a custom one from the new intercooler back to where the original would have connected to
 
Hmm I'm sure a hose off the a6 tdi twin set up might fit after all front ends are very similar
 
True....that connection is the only real tinkering it would need as even the 1.8t 190 has the twin intercooler setup
 
Hmm might start looking at this now then need to find one breaking so I can get good pictures of set ups and pipe work unless a member on hear has pics of there set ups for us to look at
 
Had a quick look and would say it's going to be a mix of parts based on the 1.8t 190 BEX setup
 
I wouldn't imagine a dual intercooler setup would offer any performance advantage over a FMIC set up, indeed I would say a suitably sized FMIC would probably offer more coolling capacity and maybe less pressure drop.
tI would have thought the main issue with fitting a second SMIC is trying to get the parts at a reasonable price and getting the turbo outlet to the SMIC top intake, could be a bit of an s shaped hose.

Karl
 
I agree with Karl above - the two side-mount coolers arent that great.
Im thinking of swapping mine on the 2.5 to an ebay FMIC kit due to one of my intercoolers being split.

Also, due to the side mount intercoolers splitting from the plastic housing - 2nd hand prices are quite high (which justifies an ebay FMIC and pipework)
 
I'm defo with Jim & Karl here, as i was reading down, my first thought was, "what's the point when you can fit an FMIC"!!!
Also a lot of ******* about when a universal FMIC takes about an hour and comes with everything you need, plus the £160 one from flee bay is good up to 300bhp.
 
AlexGSi2000 said:
I agree with Karl above - the two side-mount coolers arent that great.
Im thinking of swapping mine on the 2.5 to an ebay FMIC kit due to one of my intercoolers being split.

Also, due to the side mount intercoolers splitting from the plastic housing - 2nd hand prices are quite high (which justifies an ebay FMIC and pipework)
Click to expand...

which side is stuffed mate ?
 
Twin intercooler setup sounds real good, only thing is if the original front/side one can't be used again it might be pricey replacing the original with two new ones (or seemed it judging by the link with the guy who got them in). When I finally get around to it (which by my standards could be an eternity) I'll probably go for something like this side mount http://www.darksidedevelopments.co....i-pd130-asz-and-us-spec-bew-pd100-engine.html front mounts are probably better but I always worry about fitting as I don't really want to loose fog lights or have anything sticking out the grille.
 
The intercoolers on mine are solid alloy i dont have the ones with plastic ends, and such are much stronger from braking. I think they were fitted to the v early 2.5tdi then audi refined the costs and made a cheaper more breakeable item.
 
iv done the fmic before on my passat i realy dont want to cut my bumper up to fit it (votex front bumper) and i want it hidden, the twin pass must work well as its fitted to the v6 passat and a4/a6 and serves them very well, im only looking at this as an option and if i do go down this route ill buy off ebay i wont pay over the odds for parts ;)
 
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I have a set of oem intercoolers with the plastic ends from my A4.b7 if you are interested?. Looking for about £40 plus postage
 
Cheers I only really need drivers side cooler and pipe work you willing to split ??
 
I've got this twin setup to put in. 2.0 TDI engined b7 170bhp version, has the bracket and intercooler to fit to the driver side, need to make up some hoses to interrupt the one from the turbo down to the metal conduit below the radiators. Will add some pics tomorrow once I've got it mounted on the car.

I looked at the 1.8t setup and the intercooler ports looked like they'd be in the wrong places.

Also will need to relocate the vacuum valves/actuators that sit on the drivers wing, on top of the chassis leg.
 
Noticed Shark Performance are doing a twin inter-cooler setup on a B7 2.0tdi using/modding B5 S4 bi-turbo uprated inter-coolers
 
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Well I got on ok fitting the new intercooler, have no boost pipes connected yet as i need to order some corners and joints to fit it.

Like I said the other day, on reflection the 1.8T intercooler that takes the inlet down the back would be easier to connect using OEM hoses.

My setup is going to come from the turbo, down to the lower connection of the SMIC (as I didnt realise how low the turbo output was), then from the upper connector over the chassis leg and down to the crossover pipe to the other side of the car.

By trying to keep the in at the top - out at the bottom I would have to fit some extreme corners to connect up, and the flow would probably have been poor.

You can see in the pictures how I have fitted it, and have got a matching fog air ram/collector. The clips were different to the original N/S one so if you look to buy one, match them up from the same model of car! I have also removed the foglight assembly so there is a clear route for the air.

I have sealed the open intercooler ends with plastic and cable ties to keep out junk till I connect them properly. Relocation of the vacuum system valves is required on the 1.9 TDI. as they are mounted where the intercooler bracket is. I also had to remove the Helmholtz resevoir from the crossover pipe (black tank on small hose in drivers front corner, under the chassis leg), and block with a blanking piece and jubilee clip.















 
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If someone is in need, i have a pair of side intercoolers too, just drop me an email if interested...
 
Very interested to see how you sort out the pipe work on the drivers side cooler :) I take it the v6 turbo is not in the same place as the 1.9 tdi's then ??
 
You have to remember that the V6 intercoolers also have two pipe connections at the bottom not one like the 1.8t and 1.9tdi

$_35.JPG
 
Mike.M said:
You have to remember that the V6 intercoolers also have two pipe connections at the bottom not one like the 1.8t and 1.9tdi

$_35.JPG
Click to expand...

Hence why I bought a 2.0 TDI 170 intercooler. Single 57mm ports both for in and out.

I did notice that the 1.8t has a small outlet for the recirculate valve that would need to be blocked similar to the Helmholtz tank connection on the 1.9.

BTW guys, you can get a reasonably up to date version of ETKA online here for free with no registration: http://www.partscats.info/
If you have the right java plugin you can see all the exploded drawings alongside in each subsection too!
 
Welshquattro said:
Just spotted these on eBay,any good to you.
http://www.ebay.co.uk/itm/Audi-A4-B...arts_Vehicles_CarParts_SM&hash=item3a9bd87ecd
Click to expand...

Really wish you hadnt linked that.
I have just fitted brand new side-mounts (last night).

I was going to fabricate a FMIC, however due to needing the car pretty much every day + the cost of proper fabrication I decided to just replace the standard items.
Pressure tested my original coolers - they were leaking from loads of places.

Shame these werent listed earlier - could have saved a few hundred quid! - only round the corner too.
Ah well - at least the car feels like its pulling harder and not dropping boost.
 
Sorry Alex! :(Its always the way,they come up for sale after you buy some. But good to hear you got it sorted :)
 
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Just think they could be leaky ones also Alex.......at least you know where you stand with new ones.
 
Mike.M said:
Just think they could be leaky ones also Alex.......at least you know where you stand with new ones.
Click to expand...

Thats what im thinking - at least with the new ones there is a 12-month warranty.

Also - just by chance - the coolant header tank cracked last night - one of the points for the coolant return hose had cracked (im guessing due to heat cycles catching up with the 12-year old plastic)
Thats another job for tonight :) - this car owes me bigtime.
 
Icarus83 said:
Relocation of the vacuum system valves is required on the 1.9 TDI. as they are mounted where the intercooler bracket is. I also had to remove the Helmholtz resevoir from the crossover pipe (black tank on small hose in drivers front corner, under the chassis leg), and block with a blanking piece and jubilee clip.
Click to expand...

Does this mean a 1.9tdi will loose fogs with a 2.5/other side mount intercooler?
 
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