Intercooler change DIY

[brad]

Can anyone point me in the right direction for an intercooler change DIY for an Octy2?

thx

[zei20t]

AUDI S3 core?

bolts straight in AFAIK.

if not, make sure you get a kit that has ALL parts required. youll need to remove the front bar at the very least. not a big job.

[brad]

S3/golfR plastic tank version - an extra 7mm of core but it looks totally OEM. It's as good / possibly slightly better than the metal tank S3 unit if threads over at GolfMK6 are any indication.

I know it bolts straight in - except for possibly an issue with the alignment tabs in the connector.

My biggest issue is streamling the removal of the front end components so that I'm not removing parts unnecesarily.

I have a Golf MkV DIY from the forge motorsport site but was hoping for something slightly more targetted

[Lucas_R]

Not a DIY, but here is a pictorial that i did when i replaced my intercooler. Some of it might be helpful. There is a link to a GTI install guide which might be handy for you.

THS Copy Intercooler review and installation pictorial semi-DIY

Front bumper removal DIY (MK6 GTi): MK6 Front Bumper Removal

Intercooler instructions for MK5: https://docs.google.com/file/d/0B7H1...U2c/edit?pli=1

EDIT: Another DIY here which might be handy (MK5): http://www.golfmkv.com/forums/showthread.php?t=168162

[Lucas_R]

And if its anything like my Golf (which it probably is), remove the plastic tray under the engine, the front bumper, then headlights, then the crash bar, then the large plastic surround that houses radiator/intercooler etc. Then unbolt your a/c radiator from the front of the intercooler and also the bolts that secure the intercooler to the radiator behind it (all 3 radiators are joined together with bolts). Then disconnect the rubber hoses and it should be ready to remove.

Fit the new intercooler, fit the new hoses (make sure the green rubber seal on the drivers side hose is seated correctly to avoid leaks) and then reverse the above steps to put everything back together. Took me about 4 hours, and that included taking my time and taking pics along the way for reference.

When removing your bumper, make sure to put some sheets/towels under the front of the car to avoid scratching the bumper on your garage floor when it comes off.

[brad]

Thanks Lucas

You must have an excess of good karma around you if your helpfulness is any indication.

[Mysticality]

Whats the bet that the S3 radiator will fit a TDI?...

*And work well

[brad]

What thickness is the IC on your diesel? You can measure it at the top.

In order to know where we are travelling to, we need to know where we are starting from.

[zei20t]

Im not sure anyone has tried Matti. Worth a go I rekon.

As for the plastic and metal end-tank versions. The plastic tanked version is thicker?

I didn't know that, was going to buy the all metal one. glad I kept reading this thread!

[zei20t]

ok I see links for aftermarket ones in your thread. im gonna do this!