S3 intercooler install??

[MadMen]

Does anyone have any advice/detail on swapping the S3 intercooler? Most instructions, and all videos are for the Golf R. I figured it would be the same, but as I prepare to do this next weekend, I've found several statements that the S3 is much more difficult.

Looks like most of the difficulty is with the shroud, and requiring extensive grinding and cutting. I can find some pics, but the angles and quality make it real difficult to see what exactly was cut. I don't mind cutting plastic up, but not sure if there's metal that needs to be ground also?

Any help/advice would be great.
Thanks!

[zcspec]

Did you take a look at this guide:

http://www.ctsturbo.com/cart/images/S3FMIC.pdf

It's CTS's FMIC and I know, they do require trimming.

[MadMen]

Thanks. That’s the closest to showing the cuts it seems. Just hard to tell where some of those cuts are.

A bit frustrated that the description for the IC says no trimming required - which only pertains to an MK7, but don’t specify that :/

[zcspec]

I was planning a DIY video for the FMIC on our S3's but have too many projects at this point. If you do install it yourself, I would greatly appreciate any feedback you have.

[Rocketsauce16]

Don’t do it, take it to a professional. Getting the bigger intercooler in place b/w the condenser and radiator is a MF and the bracket that holds it all together is enclosed and not framed like on the Mk7. It took me two days about 5 hours total and mainly the phone call to a friend to get it wrapped up.


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[MadMen]

I was planning a DIY video for the FMIC on our S3's but have too many projects at this point. If you do install it yourself, I would greatly appreciate any feedback you have.

Planning to do it this coming weekend

Don’t do it, take it to a professional. Getting the bigger intercooler in place b/w the condenser and radiator is a MF and the bracket that holds it all together is enclosed and not framed like on the Mk7. It took me two days about 5 hours total and mainly the phone call to a friend to get it wrapped up.

Did you have to cut or grind any metal? That's what I can't seem to get info on. Want to make sure I have the proper tools before I start.

I'm fairly mechanically inclined - have done several motor swaps on previous cars. So complexity doesn't scare me as much as not having all the tools I need. Thanks for the heads up though, so I know to add an extra six pack to the tool list....

[Rocketsauce16]

I did not but I had the Unitronic intercooler, the toughest part is the clips that hold everything together on each side they took some patience. The other part is getting the intercooler back into the slots where it was. It took someone bench pressing from below and pulling from up top. I’m by no means a mechanic, but taking the intercooler off is a breeze and putting it back together my friend pretty much stood and watched the second time around. Not sure the size of the CTS intercooler but Unitronic s was a very tight fit.


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[MadMen]

I did not but I had the Unitronic intercooler, the toughest part is the clips that hold everything together on each side they took some patience. The other part is getting the intercooler back into the slots where it was. It took someone bench pressing from below and pulling from up top. I’m by no means a mechanic, but taking the intercooler off is a breeze and putting it back together my friend pretty much stood and watched the second time around. Not sure the size of the CTS intercooler but Unitronic s was a very tight fit.


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I have the APR. I bought extra plastic clips (the big yellow ones) in case I have to break the stock ones to get things off. I'd rather just replace parts than spend too much time trying to save them. But knowing no metal has to be cut/ground definitely makes me feel better. I figure once I get the crash bar off, I'll mark up the plastic shroud at all spots where it might make contact knowing everything behind it will push forward about an inch.

Thanks!

[zcspec]

MadMen, I personally believe that if you have the time, tools, and patience, you'll be successful with the installation. Very interested to see what you will have to say. Best of luck!

[MadMen]

MadMen, I personally believe that if you have the time, tools, and patience, you'll be successful with the installation. Very interested to see what you will have to say. Best of luck!

The wife and kids will be out of town for the weekend - so I'll be free to curse as often and loud as I need to for a few days! I'll attempt to take some pics or video, but being solo will make it difficult.

[MadMen]

All done!

Took about 7 hours solo, including lunch, a beer, and clean up. Only slight trimming of the plastic around the AC lines to allow the condenser to lift up off the intercooler. APR recommended removing the AC lines, but it was much easier, and less expensive to do some Dremel work.
No other trimming of the shroud was necessary.

I had bought an extra set of those big plastic clips, as I've read that it was likely they could break. Glad I did, cause those things were a bear to try and get out. I gave up and just broke them so they would slide ride out. Might as well make the purchase of the spares worth it. I would say that's the way to do it, instead of wasting the energy to save the originals.

The only other difficult part, was trying to get the one front bumper screw back in, the one that is deep inside the fender. I gave up after the 10th time dropping that screw in the bumper, and just decided to leave it out.

All in all, wasn't too bad. Definitely more difficult than a Golf. I imagine the Golf R would probably be a 4 hour job.

Need to soak my fingers in ice now though

[zcspec]

Well done MadMen. If you took photos or videos, I would love to incorporate them into a future DIY video I'll make for our chassis, credit to you of course.

[MadMen]

Well done MadMen. If you took photos or videos, I would love to incorporate them into a future DIY video I'll make for our chassis, credit to you of course.

Unfortunately, didn't get any pics. Ended up with washer fluid all over me, and in the eyes, so was just going as quick as I could so I could clean up :/

The CTS install instructions were pretty good. Missing a few things, but easy enough to figure out the missing parts. I mixed that with the Revo instructions which had some other good info too.