VWDiesel.net The IDI, TDI, and mTDI source.
Engine Specific Info and Questions => IDI Engine => Topic started by: erice1984 on August 21, 2010, 10:49:50 pm
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I am looking for pictures on how people have installed front mount intercoolers. I am considering using one when the turbo happens and was curious about how others have tackled this.
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Check out jack's build in the general section
Iam going to relocate my battery under the bed and use a Intercooler from cxracing.com
Size: 28 x 2.5 x 7 w, 2.5 o.d. of the tubes
I was trying to figure the mount and I will probly modify 4 of the radiator mounts that I found for my 675 mm radiator install.
I dont want all of the tubing to one side, I will have a 45 elbow coming down to the rh intercooler side
and a one 90 tube coming from the pd150 to the lh front.
I will be using black powder coted tubing with red silicone connectors, all tubing with beaded ends
azautohaus.com
part #'
191121265C
191121265B
The 28' intercooler width is plenty, as the radiator is 26.57 wide
Stay in touch...
GB
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Gee-Bee, did you mean CXRacing.com? I kind of like this kit, http://www.cxracing.com/mm5/merchant.mvc?Screen=PROD&Store_Code=CXR&Product_Code=IC0049-KIT200-EB&Category_Code=ICDK200 (http://www.cxracing.com/mm5/merchant.mvc?Screen=PROD&Store_Code=CXR&Product_Code=IC0049-KIT200-EB&Category_Code=ICDK200), since it looks pretty complete.
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Oh that intercooler looks like a good size.
Does anyone use blow off valves on diesels? if you don't use one why not?
From my understanding the BOV is designed to extend the life of the turbo.
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a BOV is unnecessary on a diesel as there is no throttle plate closing and dead heading the turbo off throttle.
on a gasser when you lift off the throttle the throttle body closes causing a very sharp increase in pressure between the turbo and throttle body, decreasing life of the turbo(often simply snapping the shaft) and sometimes blowing the intake plumbing apart.
as a diesel has no throttle plate, there is no sharp increase in pressure off throttle, and no danger to the turbo or intake plumbing.
-Owen
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Good call! Yeah, no throttle plate, makes more sense. Thanks for clarifying.
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I actually just ordered one of those CXracing intercoolers. Im probabley going to use exhasut tubing and bend it myself for the tubes. They are cheap and from what ive read seem to work pretty good.
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Yeah I have seen that done before. Steel, Aluminum, whichever is easier for you to work with.
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Correct, CXracing
RH side:1.50 to 2.50 reducer at the turbo, than a 45 bend to the rh front to 90 degree pipe to st straight coupler to intercooler
LH Side :PD150 to straight to 90 bend to straight to 90 bend into lh intercooler
My core support is from South Africa, so there is room for this after the battery is relocated
GB
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Here are some pictures of my fmic.
(http://i910.photobucket.com/albums/ac309/bhollis321/rabbit/DSC_1332.jpg)
(http://i910.photobucket.com/albums/ac309/bhollis321/rabbit/DSC_1325.jpg)
(http://i910.photobucket.com/albums/ac309/bhollis321/rabbit/DSC_1328.jpg)
(http://i910.photobucket.com/albums/ac309/bhollis321/rabbit/DSC_1338.jpg)
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hey Bugnut !
Your missing your upper radiator clip
Ebay item :
270571359731
Dont worry , My wife says I cant find it either..... :o
GB
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thanks Bugnut
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I'll save you the trouble. It looks a lot like bug nut's though
(http://i638.photobucket.com/albums/uu107/kaputtschlagen/RelocatedFilters2.jpg)
(http://i638.photobucket.com/albums/uu107/kaputtschlagen/Intercooler3.jpg)
(http://i638.photobucket.com/albums/uu107/kaputtschlagen/intercoolerMounted1.jpg)
(http://i638.photobucket.com/albums/uu107/kaputtschlagen/intercoolerMounted2.jpg)
(http://i638.photobucket.com/albums/uu107/kaputtschlagen/piping1.jpg)
I have seen guys on the vortex run the ones with one inlet on each side. however it would probably require moving the battery to the trunk or moving the radiator starboard a bit if possible. Mine won't move any further because the alternator is right there by the lower radiator hose. If you have A/C or an air/oil cooler it is going to be even more of a challenge.
I hope this is helpful, and good luck.
Cheers
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PO had already relocated battery to trunk.
No A/C
No Oil Cooler
Standard V-Belt Alt. (65amp or 55.. whatever it is)
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With all that moved Erice, it will be easy
PD150 ?
GB
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What is PD150?
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Intake manifold, see jacks car in this post, faces toward the driver's side, better performance, need to a race pipe egr delete ( streettoys 2000 ) vendor here...
GB
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Intake manifold, see jacks car in this post, faces toward the driver's side, better performance, need to a race pipe egr delete ( streettoys 2000 ) vendor here...
GB
Forget my intake. I want bugnut's custom job :o
OP if the battery is already relocated then I would def run one with the the cool air running up the port side. Assuming you can find an intake manifold that faces that way.
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The intercooler fits perfect between the frame rails with the 2.5in. 90 bends.
2in. inlet and 2.5in. outlet. It gets really tight by the battery though.
(http://i232.photobucket.com/albums/ee10/joshmarstall/IMG00206-20100819-2002.jpg).
(http://i232.photobucket.com/albums/ee10/joshmarstall/IMG00208-20100819-2002.jpg).
(http://i232.photobucket.com/albums/ee10/joshmarstall/IMG00207-20100819-2002.jpg).
G60 intake.
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What width is that one PBSpearco? I am looking at some one is 27" X 5.5" X 2.25 and the other is 28x5.5x2.5. That is overall length and it will be in a MK II Jetta with A/C eventually. I was going to try lower and in front of the condenser. If it fits like yours though I would be very pleased.
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http://www.vwwatercooled.org.au/f13/swallowtail-goodness-13409-12.html (http://www.vwwatercooled.org.au/f13/swallowtail-goodness-13409-12.html)
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Hey GLTDi
2' is how it fit so well
This is the same way I wish to plumb my IC
Cheer's to you !
GB
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Intake manifold, see jacks car in this post, faces toward the driver's side, better performance, need to a race pipe egr delete ( streettoys 2000 ) vendor here...
GB
Forget my intake. I want bugnut's custom job :o
OP if the battery is already relocated then I would def run one with the the cool air running up the port side. Assuming you can find an intake manifold that faces that way.
that intake is pure sex..
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Got the measurments of the intercooler. 29"x 6"x 2.5". That left me room for the 90's on each end to fit between the frame horns.
I'd go taller but it was free, so I built with what I was delt with. I wouldn't go more than 10" tall because of the hood latch. If you use a taller on, you need to take off some metal off from the front support as to make it sit flat against the core support.
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Intake manifold, see jacks car in this post, faces toward the driver's side, better performance, need to a race pipe egr delete ( streettoys 2000 ) vendor here...
GB
Forget my intake. I want bugnut's custom job :o
OP if the battery is already relocated then I would def run one with the the cool air running up the port side. Assuming you can find an intake manifold that faces that way.
that intake is pure sex..
If you are talking about my intake yeah that was a pain to build. Took about 35hrs of fab work.
(http://i910.photobucket.com/albums/ac309/bhollis321/rabbit/DSC_1304.jpg)
(http://i910.photobucket.com/albums/ac309/bhollis321/rabbit/DSC_1305.jpg)
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that is a beauty intake. defiantley jealous. How much more flow can you feel it gets compaired to stock?
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Look's like a 28 x5.5 x 2.5 Inter cooler with 2' Inch outlets for me
I will have to make a 45 degree elbow 1.50 x 2.00' reducer to come of the turbo ( ko3) to the pipe
or
I might try a 1.50 x 2.00 reducer straight, and get a 45 2' 45 degree pipe for 14.00.
This will get off the turbo with a downward bend to the rh front 90 degree elbow
GB
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Yeah, definitely need to figure out something for the intake manifold. I want the air to flow in from the drivers side.
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Cheap: flip the inlet around
PD150 with racepipe
passenger performance used
GB
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will a gasser intake manifold fit with a T3 turbo?
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Yes it will. Only with the right ex. manifold.
I'm using a T3 turbo from a Merc. 300TD bolted to an ebay ex. manifold all mounted in a VW truck.
The underside of the gasser intake, depending if its a MK1 or MK2, needs to be clearanced.
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was looking at a digi from a 91 fox.
the factory exhaust "log" manifold wont work?
Something like this:
http://cgi.ebay.com/ebaymotors/VW-8V-CAST-IRON-TURBO-EXHAUST-MANIFOLD-GOLF-JETTA-T3-/280552131590?pt=Motors_Car_Truck_Parts_Accessories (http://cgi.ebay.com/ebaymotors/VW-8V-CAST-IRON-TURBO-EXHAUST-MANIFOLD-GOLF-JETTA-T3-/280552131590?pt=Motors_Car_Truck_Parts_Accessories)
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As fas as the factory log manifold. Which one.
Yep, thats the same one I'm running, but coated inside and out.
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awesome.. digi gasser intake and ebay ex manifold..
just got to find t3 with correct square flange.
like this manifold
(http://www.turbosandparts.com/images/028253033Q.jpg)
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That manifold is from a AHU TDI. It uses a GT15 turbo. Of corse you could make an adapter, but if your going that far, may as well build a custom one for what you want, where you want.
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What did you do for waste gate? Use internal or external?
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The turbo has an internal wastegate. Opens at 11.5 psi.
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will a gasser intake manifold fit with a T3 turbo?
only with a VNT manifold. and that happens to be the intake im running, they rock for stock VW manifolds.