Fitting front mount intercooler.

JORDY - A3

JORDY - A3

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Just a quick question...

How much work is it to fit a front mount intercooler?

Thanks!
 
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I have a 2001 s3 and i bought a Airtec intercooler and engine code is amk. Looking at the instructions it doesn't look like it should take more than a hour and half for any good mechanic only bit is crash bar needs cut a bit.
 
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How have people tackled cutting the crash bar anyway? Hacksaw?! LOL

A shop shouldn't take any longer than a couple hours since they should have all the tools required.

No hackaway front mount
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It's going to take you more than an hour, you have to remove the front bumper, all the old cooler stuff, and the fit most probably 3-4 hours, did you order a joiner pipe to joint the charge pipe to the drivers side cooler pipe? As you will need one,
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Then there's the trimming and re trimming little by little to make sure you retain fog lights etc, relocating the horn and I removed both headlights two get more room to get the pipes on as there tight bumper isn't easy to get back on because the horns aren't really any good there,


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You keep keep the fog lights, I will take a couple pics tomorrow, but will take longer than your estimated time unless you have an extra pair of hands


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I posted this in the wrong thread and got told of for it lol. I said id post a pick of it going on and as westcoast a3 said it took them about 6-7 hours to get it all fitted and trimed right.
 
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I see you've joined the airtec kit to the standard intake pipe on the right hand side of the car, is this not restricting the flow?
 
hydro s3 said:
View attachment 107888 View attachment 107887 I posted this in the wrong thread and got told of for it lol. I said id post a pick of it going on and as westcoast a3 said it took them about 6-7 hours to get it all fitted and trimed right.
Click to expand...

I am glad you put up the hours it took, did the fitters say why it took so long or is that simply the time it takes - that's about £1000 to buy and fit? Or was the bumper and lights difficult to get off - making it awkward.
Thanks
 
Jutchops said:
I see you've joined the airtec kit to the standard intake pipe on the right hand side of the car, is this not restricting the flow?
Click to expand...
Im not sure why its connected there. I had left it in to a garage to get fitted as i just thought they would do it better. Where should it be connected to? It is a bit late now to get it joined any where else but ur advice on this would be appropriated.
 
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Stuart B said:
I am glad you put up the hours it took, did the fitters say why it took so long or is that simply the time it takes - that's about £1000 to buy and fit? Or was the bumper and lights difficult to get off - making it awkward.
Thanks
Click to expand...
They said most of the time was in cutting the crash bar and trimming the fog light grills they alao had to cut a bracket of each fog light to get it to fit back on. The horn and ambient temperature sensor had to be moved up to behind the audi sign with caused them a bit of a problem to get the bumber on properly. They only charged me 4 hours labour cause they said thats what they had quote me so that was good of them. The intercooler was £465 delivered i live in Northern Ireland so it cost more to ship it over and then £240+ vat so all in just over £700 which i think is good.
 
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hydro s3 said:
Im not sure why its connected there. I had left it in to a garage to get fitted as i just thought they would do it better. Where should it be connected to? It is a bit late now to get it joined any where else but ur advice on this would be appropriated.
Click to expand...

OE map pipe while arguably a restriction is not going to affect power on a std K04..You can buy a 63mm MAP sensor tube from places such as Forge but it will take a bit of fiddling and trimming to get it to fit correctly...

I wouldn't worry too much about it at this time

<tuffty/>
 
<tuffty/> said:
OE map pipe while arguably a restriction is not going to affect power on a std K04..You can buy a 63mm MAP sensor tube from places such as Forge but it will take a bit of fiddling and trimming to get it to fit correctly...

I wouldn't worry too much about it at this time

<tuffty/>
Click to expand...
When should i start to worry about it? Why in my post number 15 say last edited by a moderator? What did i say that was wrong?
 
I've had issues either bumper fitting as well with the horn in that position, I did say it's a bit to'ing and fro'ing as such. I think I am going to mount my horn some where else as, I am
Going to honey comb style mesh my front grills and don't want the horns seen


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hydro s3 said:
When should i start to worry about it?
Click to expand...

...if you go big turbo... I don't know off hand if the Airtec pipework is 60mm or 63mm... if its 60mm then there is not much to be gained... if its 63mm you could argue its a potential bottle neck but realistically I doubt its going to make enough difference to lose sleep over at this time... if you end up having a bunch of work done to either go hybrid or big turbo then thats the time to address it..especially if you are paying someone to do the work... aftermarket MAP sensor tubes often require a little faffing to fit due to the tight space where they run...

hydro s3 said:
Why in my post number 15 say last edited by a moderator? What did i say that was wrong?
Click to expand...

Removed txt speak...

<tuffty/>
 
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westcoast a3 said:
Really ?? When I measured the inlet outlet in the cooler it measured 63m that's why I bought 63mm joiner pipe as well


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Click to expand...

is this measurement inner diameter or outer diameter?
 
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