The intercooler will help a very little bit at lower boost levels. Really about 10 PSI is where the compressed air from the turbo starts becoming "hot" and then it just goes up from there. Diesels like boost - there is nothing at all wrong with feeding more COOLED air to your engine.
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If there is more air you should see it burn a bit better. It should make your turbo and engine happier to be running cooler so they should live longer. I got better mpg with it as I think because of it running cooler added power so I wasn't into the pedal to get it to move. When you heat soak everything it gets less and less responsive, so you have to run it harder, and then it gets hotter yet. You will see at least a 200f drop in your highest egt, I did.
If there is more air you should see it burn a bit better. It should make your turbo and engine happier to be running cooler so they should live longer. I got better mpg with it as I think because of it running cooler added power so I wasn't into the pedal to get it to move. When you heat soak everything it gets less and less responsive, so you have to run it harder, and then it gets hotter yet. You will see at least a 200f drop in your highest egt, I did.
Seems like a fun experiment I could deal with in my crippled state.
So I am am all stock with a 1.6td and am using mk2 airbox in a rabbit with no ac, stock regular radiator. Any clue if I could wiggle this in there?
And would I buy some generic 2" intercooler piping kit on ebay and just hope for the best routing wise that I get enough material?
That little neck on the manifold thats connected with the 90 degree hose, would I have to turn that thing 180 degrees?
I'd spend some time with a tape measure and plan out how to run your piping rather than buying a "universal" kit and hoping for the best. Draw it all out on paper and triple check, then you can just order what you need.
Yup, you can flip the neck around on the intake easily enough.
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Yeah, I flipped mine 180 and I did buy a universal kit. I cut up what I needed and added where I needed. Worked for me as it was cheaper to do the kit than it was to order from frozen boost at the time. You would just have to figure it for yourself what works best.
you can get the cheap china made stuff at siliconeintakes.com
make sure you bead your tubing ends or you will blow them off
Price drop bump.
60.00 shipped USA