Fitting an Airtec Front Mount Intercooler?

[Ricky Burrows]

So i keep putting this off as other things keep popping up and i don't fancy doing it in the rain but when the weather allows I'm looking for some advice on fitting the airtec fmic on my 2.0 tfsi, its still in the box and tbh its flipping massive and in the way of everything.

So if anyone has fitted this before or another brand of fmic are there any specific tools you need and basically is it straight forward as I'm really not a mechanic but ill definitely give anything a go, it will be a life saver if someone has an idea of what ill need and where to start, rough time it will take ect? Basically be my instructions as ill literally just make it up as i go along otherwise which generally works but i don't fancy taking that route on this one lol.

Thanks

 

[Ricky Burrows]

To give you an idea of what your working with im not even sure where the pipes go I'm assuming ones hot and ones cold obviously but where they go i have no idea....

 

[Ricky Burrows]

This car is my first turbo petrol so im a tad unfamiliar with the workings of it hence why i want/need to start doing things myself.

 

[Bluepower]

there are several DIY on Youtube, most of them not Airtec specific, but it will give you a general idea of what you can encounter fitting it!
But from what I understand, it's a nice piece of kit, and worth the costs.
Btw, once you've got the bumper off(20 minutes of work) you can reach most of the things quite easily

 

[Ricky Burrows]

Just seeing that video alone has given me a huge help and understanding where things are going, thanks! it looks fairly straight forward as well so if the weather is good this weekend me and the boy will get it fitted.

 

[Charlie Farley]

I think a few B7 owners have the same unit fitted on their cars, I expect one will be along very soon to enlighten you Ricky , well all of us really.

 

[Ricky Burrows]

I think a few B7 owners have the same unit fitted on their cars, I expect one will be along very soon to enlighten you Ricky , well all of us really.

Yeah i thought there would be a few floating around on here

 

[Adi s dtm]

I have fitted that intercooler it’s not a hard job you have to relocate the outside air temperature sensor and remove the crash bar at the front, there is full instructions with the kit, just remove the bumper first, tool wise you will need a long torx 30 driver to release the two hight adjusters for the bumper on the crash bar the rest is normal sockets, the only problem I had was the map sensor hole was too large and I needed a bigger adapter to fit it correctly and seal.

 

[Adi s dtm]

This is the adapter seal I used for the map sensor.

 

[Charlie Farley]

I have fitted that intercooler it’s not a hard job you have to relocate the outside air temperature sensor and remove the crash bar at the front, there is full instructions with the kit, just remove the bumper first, tool wise you will need a long torx 30 driver to release the two hight adjusters for the bumper on the crash bar the rest is normal sockets, the only problem I had was the map sensor hole was too large and I needed a bigger adapter to fit it correctly and seal.

Was the headlamp removal needed to fit the FMIC or for another reason?

 

[Adi s dtm]

I did it to remove the old intercoolers with plenty of room.

 

[Adi s dtm]

Sent from my iPhone using Tapatalk

 

[Charlie Farley]

Ok .

 

[Ricky Burrows]

This is the adapter seal I used for the map sensor.

Was this the only thing you used to solve the map sensor issue? Ill order this now i didn't know if there’s anything else you used as im assuming ill have the same issue with the sensor.

 

[Adi s dtm]

You can check your sensor by removing it and checking the size, I found it to be the best type for mine yes it’s a rubber seal that is a tight fit on the sensor and in the cooler pipe so won’t leak.

 

[Ricky Burrows]

You can check your sensor by removing it and checking the size, I found it to be the best type for mine yes it’s a rubber seal that is a tight fit on the sensor and in the cooler pipe so won’t leak.

Ive ordered it already and got bummed on the postage £4!! For a flipping £4.60 part, but thank you that would of been a pain in the *** finding that out while in bits on a Sunday afternoon.

 

[Adi s dtm]

That’s what happened to me, I managed to find a flat seal as a temporary fix before fitting that seal.

 

[Ricky Burrows]

That’s what happened to me, I managed to find a flat seal as a temporary fix before fitting that seal.

Bit of a joke considering airtec are meant to be good quality and its specific for that car for £550 they could of thrown in a £5 bung!

 

[Adi s dtm]

Bit of a joke considering airtec are meant to be good quality and its specific for that car for £550 they could of thrown in a £5 bung!

To be fair the company I got mine from sent me a metal adapter but it wanted to drop straight through the hole and I did not want to risk it damaging any engine parts so used the other seal.

 

[Ricky Burrows]

To be fair the company I got mine from sent me a metal adapter but it wanted to drop straight through the hole and I did not want to risk it damaging any engine parts so used the other seal.

Ill have to have a look at it all then as I've only pulled out the intercooler it self the rest of the stuff is wrapped up still, i got mine from airtec direct so if it don't come with everything i need id be a disappointed, but the map reducing bung will be there as a fail safe.

 

[Sidrick]

Went to fit mine today. A said, it came with a metal bung but it's absolutely not air tight. Shall need to look at the rubber bung above.

 

[Ricky Burrows]

Went to fit mine today. A said, it came with a metal bung but it's absolutely not air tight. Shall need to look at the rubber bung above.

I got the rubber bung here as a back up and i had the metal one that come with the airtec kit i thought it fit really well so i kept the metal one on and the car seems to run really well, obviously a boost gauge would come in handy to know the psi but it seems to pull better than before especially in 2nd for some reason

Any other ways of telling if it’s slightly leaking?

 

[Sidrick]

Yeah, it seemed very snug but it needs to be airtight. My test was very basic. bolted down the map sensor, wrapped a glove around it, blocked off one end and blew in the other, lol. Definitely leaky.

 

[Ricky Burrows]

Yeah, it seemed very snug but it needs to be airtight. My test was very basic. bolted down the map sensor, wrapped a glove around it, blocked off one end and blew in the other, lol. Definitely leaky.

Thanks for the heads up ill swap it for the rubber bung

 

[Sidrick]

Ricky, any pics of how your PAS cooler is mounted? The pathetic airtec instructions show it rotated to fit to the bottom of the intercooler, but I can't see how this is possible. Adi's above just shows it angled down but I'm concerned that may foul the bumper.

 

[Charlie Farley]

These airtec IC's don't seem to be that good given what they cost, poor instructions and iffy bits, not really what one would expect given the £500 plus price tag.

 

[Ricky Burrows]

Ricky, any pics of how your PAS cooler is mounted? The pathetic airtec instructions show it rotated to fit to the bottom of the intercooler, but I can't see how this is possible. Adi's above just shows it angled down but I'm concerned that may foul the bumper.

Where the pas originally mounts cut of the excess plastic trim around it so you just have the half moon shape if that makes sense, then its literally just trying to pit the supplied clip and bolt through while trying to angle it into the intercoolers thread underneath.

Its a bit tricky and i used a few swear words but i just about got there unfortunately i only have the pictures i took unless you can zoom in maybe your see where i cut?

 

[norad97]

I would like to ask again, when you change the crash bar, what about the bumper hight adjusters ??

 

[Ricky Burrows]

I would like to ask again, when you change the crash bar, what about the bumper hight adjusters ??

No where to re fit them unless you rivot them back on I guess but mine seems to be ok and never heard of an issue with anyone else’s using the airtec.

 

[Ricky Burrows]

These airtec IC's don't seem to be that good given what they cost, poor instructions and iffy bits, not really what one would expect given the £500 plus price tag.

Totally agree mate instructions were useless common sense got me through, i guess thats why there only £550 and some others go for £700+ but still it’s decent overall just minor things could of easily been changed to make it a great little buy instead its average.

 

[norad97]

Ok Thanks, so how do you adjust the bumper hight?

 

[Ricky Burrows]

Ok Thanks, so how do you adjust the bumper hight?

I don't think you can tbh I'm not sure if airtec have took that into consideration and maybe made the crash bar around that if it’s possible? Not sure really, either way it seems ok to me

 

[norad97]

I just watched a video on an A4 B7 Airtech FMC, the one in the video is fits under the Audi crash bar?
So you don't change the bar, I see the one in the picture in this post the FMC is much bigger and could affect the radiator.

 

[Charlie Farley]

Probably why I went with the JH performance one , but i'll let you know when its fitted which maybe sooner than later now.



w.

Brilliant Black Avant quattro 2.0tfsi Special Edition 270bhp

 

[Ricky Burrows]

I just watched a video on an A4 B7 Airtech FMC, the one in the video is fits under the Audi crash bar?
So you don't change the bar, I see the one in the picture in this post the FMC is much bigger and could affect the radiator.

Haven’t noticed any issues with cooling yet while its been over 20 degrees.

 

[Charlie Farley]

Haven’t noticed any issues with cooling yet while its been over 20 degrees.

Does your b7 have single or dual fans Ricky.

 

[Ricky Burrows]

Does your b7 have single or dual fans Ricky.

Is it bad if i don't know? Lol really not sure Rob would ours not be the same?

 

[Ricky Burrows]

I just watched a video on an A4 B7 Airtech FMC, the one in the video is fits under the Audi crash bar?
So you don't change the bar, I see the one in the picture in this post the FMC is much bigger and could affect the radiator.

Me personally i wouldn't bother with an intercooler thats keeping the stock crash bar it just makes no sense half of it will hide behind that crash bar and its not got holes for cooling either so defeats the object of a front mount tbh and you cant fit one much thicker than the airtec as its close between radiator and bumper anyway but obviously its swings and roundabouts with these things, not sure if its just me from my jap car days but most front mounts actually bin the crash bar and there’s nothing behind the bumper anyway so i think airtec is good in the fact its suppling a crash bar that has holes and relocating certain things like the cooler and temp sensor ect, its still a hefty modification that wasn't meant to be there from factory so overall if your looking at one id still recommend it just invest in a bung from darkside lol.

 

[Sidrick]

Probably why I went with the JH performance one , but i'll let you know when its fitted which maybe sooner than later now.



w.

Brilliant Black Avant quattro 2.0tfsi Special Edition 270bhp

Just read the fitting instructions as I was keen to see where they put the PAS cooler. They cut the crash bar in half.

 

[Charlie Farley]

Just read the fitting instructions as I was keen to see where they put the PAS cooler. They cut the crash bar in half.