uprated intercooler

[NicholasP]

Hi guys,

been on the phone to Allard, the VW tuning specialists discussing power upgrades. They've suggested changing the EGR, inlet manifold, and intercooler together or separately depending on how much power I want..

For an uprated intercooler fitted, they was £800...

Why an earth is this component so expensive? What does it do?

I have only chipped my car, and really only want one more performance upgrade...

I was thinking of putting a real performance induction kit, £250..changing the manifold, £150, the EGR, and changing the exhaust...

Should I just change the intercooler instead?

bit confused as you can see..

[devonutopia]

If you're chipped already, the intercooler would warrant getting the chip re-done. Essentially you have to imagine the air being pushed out the turbo is HOT, it can get extremely hot, especially in the summer. Your standard intercooler cannot cool this air down, which causes hot air to get in the engine, and this is sensed by the engine and it retards the power to preserve the engine - this is heatsoak. Chipped cars with side mounted ICs tend to suffer with this in the summer. A front mount will cool down this air much more effectively so you get better power, and it is consistent through the rev range and in all gears. A seriously worthwhile modification, but one I would always recommend doing before getting the software changed (hardware first, then software - which utilises the hardware to get the best result)

Induction kit - wouldn't bother - stick a panel filter in if need be, but not really essential for power. EGR blocking off kit is something good - I have Allards one - I have the engine light on 24/7, but it doesn't bother me as I have vag com to keep my eye on the car's ECU faults. Exhaust is worthwhile too - Straight through pipe is the best, or if you fancy it - Allards "Turbine" exhaust downpipe.

How about a new turbo from Allards? VT5 good for 260+ bhp.

[Eshrules]

If you're chipped already, the intercooler would warrant getting the chip re-done. Essentially you have to imagine the air being pushed out the turbo is HOT, it can get extremely hot, especially in the summer. Your standard intercooler cannot cool this air down, which causes hot air to get in the engine, and this is sensed by the engine and it retards the power to preserve the engine - this is heatsoak. Chipped cars with side mounted ICs tend to suffer with this in the summer. A front mount will cool down this air much more effectively so you get better power, and it is consistent through the rev range and in all gears. A seriously worthwhile modification, but one I would always recommend doing before getting the software changed (hardware first, then software - which utilises the hardware to get the best result)

Induction kit - wouldn't bother - stick a panel filter in if need be, but not really essential for power. EGR blocking off kit is something good - I have Allards one - I have the engine light on 24/7, but it doesn't bother me as I have vag com to keep my eye on the car's ECU faults. Exhaust is worthwhile too - Straight through pipe is the best, or if you fancy it - Allards "Turbine" exhaust downpipe.

How about a new turbo from Allards? VT5 good for 260+ bhp.

my mate with his bora (remapped and custom hoses on the way) has also done this EGR block, what does this actually gain by doing it?

[NicholasP]

thanks for your replies guys..

I can't afford any major mods really..Im on 116bhp.

For peace of mind, i want it up to 130bhp..and then ill draw the line


Thing is, I have already chipped it...cost me 260 of hard earned cash and allard want another 400 to remap again..

That will make this operation majorly costly.

So what are my option exactly?

Change the exhaust?
Change the turbo?
Change the intercooler?

They're all big jobs..I think id only want to do one...

[devonutopia]

Well, I would say biggest bang for buck is hybrid turbo and just go easy on the remap. You only need to compare the side mounted IC to a front mounted one to tell the difference. Also note the side mounted IC is hidden behind the bumper so does not get direct airflow - my front mounted one is exposed 95% to oncoming air.

Side mounted down there in bottom right side of car (note this is not my car now but one I crashed and broke for spares 3 years ago)



And my current front mounted IC

[NicholasP]

so you reckon i should speak to allard about changing the turbo?

Car has done 150k...would an intercooler not be a 'safer' option as such...?

I do want more power though....

thanks jason

[devonutopia]

Like all tuning, you can't really do one thing without thinking about the tolerances of other bits. On a standard 90hp Golf, I personally would not remap it on standard gear to more than 120bhp. (which you're pretty much at now)

Changing the turbo will only accentuate the heatsoak issue I mentioned. Pushing more air, more force, more heat. That air will need cooling. I reckon you could get cheaper FMICs but Allards will be a complete turbo to manifold kit including pipework, bends, etc - It was on my Fabia FMIC they built anyway.

OK, so you're uprated the turbo & FMIC - lots of dosh spent, Remapped it - now running say 160bhp... Whoops, we still have a 90bhp clutch fitted.... Uprated clutch will be around £400+. At the point of changing turbo, FMIC and clutch, you've got much better spec for big power.

I would say turbo, intercooler and clutch are the "big three" in TDI tuning terms (omitting the remap needed at the end to make use of all this lot)

Don't worry about the mileage - That engine is just about run in now.

[NicholasP]

well Jason..

it doesn't really seem worth it i suppose...the big three sound great but all in all, we're looking at £2000...

The car cost £1000....

And after the big 3...ill just be waiting for some component to go under the strain which will cost even more

I guess spending that sort of money on a nice new car with 10k on the clock seems alright, but not a car that has about 2-3 years left on it...

Should I leave it, as is? or are there any minor upgrades you would suggest? extra few hp here and there? I think im facing the common problem of a twenty year old, where I want to rocket about everywhere!

[Eshrules]

well Jason..

it doesn't really seem worth it i suppose...the big three sound great but all in all, we're looking at £2000...

The car cost £1000....

And after the big 3...ill just be waiting for some component to go under the strain which will cost even more

I guess spending that sort of money on a nice new car with 10k on the clock seems alright, but not a car that has about 2-3 years left on it...

Should I leave it, as is? or are there any minor upgrades you would suggest? extra few hp here and there? I think im facing the common problem of a twenty year old, where I want to rocket about everywhere!

i totally respect your point and understand what you're saying, but dont foget that when you customize a car, be it engine or body, it wont necessarily appreciate in value. you can actually lose value off your car by customising it. ie, if you're going to customize at all, do it well.... often leads to a small fortune being spent. there are 2 ways of looking at it, spend 3/4k on modding the engine and installing the bits mentioned, have your car as individual as yourself and awesome performance. you do have high mileage, but theres no reason why anything should fail as long as the correct parts are uprated and the rest maintained properly.

second way of looking at it, save the 3/4 k, add it onto a decent(ish) part ex of your existing golf and upgrade to a more powerful car...

if i had the money to throw around (dont we all wish LOL) id be doing my golf up, but for now, 115 will do LOL

[mojogoes]

I agree with most of what has been said...so if you can't afford to buy a new more powerfull tdi go with modding yours...but don't forget that if you do the big 3 you will also need to upgrade your brakes and suspension....either use a T25 with a 360 thrust bearing or a vnt17 depending on which setup you have vnt17=vacuum/waste-gate=boost t25.


MoJo soon to have 250hp +