New Intercooler Mounting Idea

[Dewey]

I think my only other logical option is a FMIC, tucked behind the opening of the bumper, not much room with the AC condenser, and not much room to run tubing lines to the front either.

Thats how i fit mine. Car is equipped with AC (nice and cold too  ) and an oil cooler fastened to the backside of the intercooler. It is a tight fit, the bumper is trimmed to clear and the lower rad support bracket had to be removed. 1.9 with a 1.6 head, 20psi, some pump mods, and it has never gotten hot. (the "vents" seen in the plate recess are no longer there)



I also ran my intercooler piping as seen here. Not the most efficient routing due to length of the piping (close to 5 feet was used) but i only experienced a 2psi drop across the entire system. Turned the airbox on its side, cut the bottom of it out, ran the hot side down through a factory hole in the inner fender, and the cold side is run between the tranny and PS resevior, with a couple bends to connect everything under the car.

[Rabbit on Roids]

omg... that is one sexy blue jetta.

[Doakster]

Dewey....nice setup, how much did you have to cut out of the front bumper, to get the IC to fit?

Also, how does the radiator hold up with no lower support?

[Dewey]

Dewey....nice setup, how much did you have to cut out of the front bumper, to get the IC to fit?

Also, how does the radiator hold up with no lower support?

The lower crossmember, which supports the rad, is still there, what i did remove was just the one bolt, in the center, at the very bottom of the rad support (what the headlights, grill and top rad mounts are attatched too).

As for how much i trimmed, i just kept trimming until the fit was nice and tight, this pic shows about how much i had too trim.



I can get measurements of the intercooler since the car is in pieces at the moment. the intercooler is a Yonaka unit, flows pretty good, and has been good for my needs. This is how it is mounted. Super simple, not too much is covered by the bumper, the temp difference side to side of the intercooler is noticable by touch. (this is an old pic, roughly 2 years ago, but car is in the same amount of disassembly now, never ending projects it seems  )

[Doakster]

Looks nice, might have to do something similar

[Dewey]

omg... that is one sexy blue jetta.

Thank you very much for the kind words . Im very proud of the work ive done and the way its turned out.

[Smokey Eddy]

Yeah that was my biggest concern as far as not being efficient, would be convenient for a mounting location, but don't think it would be best for heat transfer.  

I think my only other logical option is a FMIC, tucked behind the opening of the bumper, not much room with the AC condenser, and not much room to run tubing lines to the front either.

lots of us have  done FMIC. me for example...
slightly larger than dewey's. It's almost 4 inches thick, i had to remove a lot of bumper material.
And like dewey's mine is very noticeably cooler from one side to the other. like night & day. mine cools well enough that i can touch the intake manifold and it's relatively cool.
minor modification required.

[polo_td]

Hi.
If u use the MB sprinter IC u brob. dont need to do so much modifying.
Otherwise the BMW 525tds IC is a small one aswell.
Take a look at them.

here´s pic of the BMW´s
24" between in/outlets.
3" thick
3" high.




thomas

[nime01]

Finally finished mounting my IC, as the HG went bust some time ago, replaced with AAZ HG now! Noticeable difference, the intake manifold is ice cold to the touch, even after some inspired driving on max boost (set at 1.4 bar/20 PSI)

Before connecting the IC, EGTs were at 754℃ max, now I'm struggling to reach over 662℃, i.e. a 92℃ reduction in EGT. So there is some cooling going on..

[rallydiesel]

What kind of tubing is that black stuff?

[truckinwagen]

you mena what smokey eddy is using?

its ABS pipe, commonly used for drain, waste and vent piping in construction.

it is very robust, resists heat transfer and will hold a remarkable amount of pressure.
it is also easy to assemble with a hand saw, ABS cement and the appropriate couplers.

I thought of using it as well, but went for aluminized steel tubing and silicone couplers.

[stewardc]

But you have a turbo and intercooler on an engine with a NA pump. It must work like crap.

[rallydiesel]

I mean what nime01 is using.

[truckinwagen]

looks like reinforced silicone to me.

just like a coupler, but longer.

[somolovitch3]

If you do not mind modifying hood, place the IC above the space between the radiator and the engine. Using a reverse "scoop" to modify the airflow, and a "real" scoop to get "cool" air to your intake.