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Custom front-mount intercooler.

AlexGSi2000 Nov 12, 2014

  1. AlexGSi2000

    AlexGSi2000 Well-Known Member VCDS Map User

    After some pointers and advice on this one if possible!

    I have traced two oil leaks back to my intercoolers on the 2.5TDi o_O - pressure tested them and found them to be split from where the core meets the plastic end caps.

    I have taken a look for replacements - they seem to be quite expensive, plus I fear they may split again due to the car running higher than standard boost pressure.
    Used intercoolers seem to be few and far betweeen also.

    As I had the front of the car dismantled yesterday I figured it may be best to go along the route of a front-mounted intercooler.
    I have seen a few universal kits on ebay with a selection of pipework, but unsure as to how good the quality is, I am thinking of finding a fabricators and supplying them with measurements, pictures and dimensions to see what they can do.

    Before I do so, I have never had an intercooler fabricated before, is it difficult work on the 2.5TDi B6?
    I fitted a forge intercooler to my Ibiza cupra years ago, but that was an out of the box kit.
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  3. ruffrida

    ruffrida Well-Known Member

    Heard of a few people fitting the universal 1 from flee bay with no problems.
  4. olethalb

    olethalb Active Member

    i think i have a pair from my dtm that should fit depending on connections you can have for cheap
  5. AlexGSi2000

    AlexGSi2000 Well-Known Member VCDS Map User

    Thanks for the offer - there are a lot of variations! I did manage to get hold of one from a B7 2.5TDi - intercooler was pretty much the same but with a number of slight differences that made it impossible to fit!
    The TFSi coolers will be very different.
  6. adamss24

    adamss24 Well-Known Member

    You might be able to fit a 1.8T passat intercooler, however it's not an easy task and you may need a selection of bends and couplers... I wish you were closer to N. London, i could build you a FMIC pretty easily ! Got welding gear and a decent kitted garage...
  7. dale86

    dale86 Member

    I'm in the process of doing the same on my 1.9tdi I have just bought a Toyo sports cooler and will be mounting this up first then me and my mate are gona use some 2.5 inch stainless tubing and fab the pipes to fit. I imported a bead roller from America to make sure the ends would not blow off as I could not find anything in this country lol.

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