d.i.y aftermarket intercooler setup

[euronyc]

anyone running a aftermarket intercooler setup? please post detailed pics if you have thanks.

my car came with a aftermarket intercooler bolt on setup and get rid of the but where the diverter valve goes previous owner capped off.


sorry for the bad pics due to the lighting.

the reason for this post is i want to clean up all my cels and this is the last thing i need to fix before starting up the car with all the new parts that was installed.


here's what was capped off (had to bend the hose up to take the pic)









FYI: im pretty sure it has a blow off valve somewhere because you can here it when you rev the car. pretty loud and i know these arent good for our cars.

[A4-Mike]

Dv goes in-between intercooler pipe and turbo intake pipe

Sent from my E6653 using Tapatalk

[euronyc]

thanks on the reply but the aftermarket intercooler piping is not routed the same way as the oem rubber hose. i dont even see a way to make the connection


intercooler is made by racetec

this is the only info i can find
http://pgperformance.com/race-tec-a4...tercooler.html


http://www.racetec-us.com/b6a4.html

[customa4]

This should help you get it set up properly. Click

[Seerlah]

That is a quality intercooler. Keep it, but def clean up how the PO had it configured. The bov/dv will be somewhere on the charge pipe from the turbo compressor outlet to the throttle body. If it is a bov, which it sounds by your description, place a a full recirculation diverter valve there and plumb the other port of the dv to the open port on the red turbo inlet port. The rotted vacuum line that runs accross the front of the upper timing belt cover (I suggest you replace that line with a silicone one) should lead right to it, off one of the solenoid valves (n112 or n249) under the intake manifold.

When it comes to the unplugged electrical connector, that is your n75 valve (stock electric boost controller). Find the other end of the connector and plug it back in. The plastic going into the port above the open one should be your pcv system, to have this blow by be attmpted to be burned in the combustion chamber. Other than that, you should have one more item to be plumbed into the TIP. That should be your n80 valve (gas tank vent) route to also be dumped back into the combustion chamber to be burned. But since you have an aftermarket intake setup, be sure your secondary injection system has a smaller filter (1") on it. If the SAI pump was removed, inspect how the PO went about it and correct any issue you feel may have been done improperly (if any).

[eljay]

Follow the advice above.
Here's a factory diagram that should help:

[A4-Mike]

thanks on the reply but the aftermarket intercooler piping is not routed the same way as the oem rubber hose. i dont even see a way to make the connection


intercooler is made by racetec

this is the only info i can find
http://pgperformance.com/race-tec-a4...tercooler.html


http://www.racetec-us.com/b6a4.html

Connect from here to dv then to turbo intake pipe

Sent from my E6653 using Tapatalk

[euronyc]

thanks man you was right it was really dirty and cleaned it up alittle. now the problem is where does the side connects to ?

[euronyc]

so the open port on the right connects to the hose that was cut and capped off?

also which way does the maf sensor goes? facing up or facing to the side?


thanks on the help guys really needed it

[customa4]

Some good pictures taken from the 1.8T engine strengthening thread. Click

This is a bit out of nowhere but since I never posted pics of my ER to Forge TIP swap, figured this would be a good addition.

The N75. Just came up in another thread and quite often at that. The N75 is the device attached directly to the TIP (unsure if this varies in the 02, but pretty sure it's the same).

Tyler explains it well here:




Attaches directly to the TIP...


And still in the bay, with the TIP removed...


And attached to the OEM TIP.



And here's a shot of the turbo side of the Forge just for kicks. It was really easy to install.

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[texasboy21]

Your car is a basket case lol. Keep inspecting and youll find all the faults. A little researching wont hurt either.

All of the codes reference an 'open circuit' - that means the harness is likely damaged.

http://wiki.ross-tech.com/wiki/index.php/17763/P1355

Might be a good idea install a replacement coilpack harness, after some troubleshooting to confirm the cause of course.