B6 A4 Dual Intercooler Installation

[1/4 scale]

B6 A4 DUAL INTERCOOLER INSTALL
(posted by 1/4 scale 9 March 2005)

Here are instructions for those interested in installing the Euro OEM dual (right side) intercooler. This system was installed as standard equipment on the 190hp version of the B6 A4 1.8T offered between 2003-2005 in Europe.

The parts can be sourced separately or from Greedspeed (currently a $850.00 kit as of the date of these instructions). I picked up this kit "used" from an AZ member at a cost savings.

Here are the pieces included in the kit:

http://www.audizine.com/gallery/data/500/10711071IMG_1388.jpg


There are pros and cons of this kit over aftermarket front mount coolers. I choose the dual system given it is OEM quality without fitment issues, and also because it was engineered to work without problems (pressure drops quality issues, etc.). I also feel that the DSMIC doesn't create any cooling problems that FMICs might create by being mounted in front of the AC and radiator panels at the front of the car. Also, this kit doesn't require any modifications to the stock bumper. The down side is that the DSMIC set up doesn't have as much cooling surface area as aftermarket units.

Such a modification is subject to owner preference however, hence this system fits my current and future upgrades given my aim of retaining as much as possible a stock look to the car.

This system can be installed with simple hand tools by one person. You'll need jack stands, or better, a lift to access the underside of the engine compartment. You should give yourself a minimum of 6 hours of install time if you are attempting this for the first time.

Below are the parts and layout of the dual intercoolers:

http://www.audizine.com/gallery/data/500/1071DSMIC_1.jpg


Also, it may be helpful to review the smog pump components (stock single intercooler arrangement shown below) as the new setup relocates the pump to the existing location of the boost reservoir (which is removed):

http://www.audizine.com/gallery/data/500/10711071SmogPump_1.jpg


Step 1:
Begin by jacking up the front end and supporting safely on jack stands (or lift). Remove front wheels and plastic belly pan.

http://www.audizine.com/gallery/data/500/1071107101_1.jpg


Step 2:
Remove front wheel liners on both sides of the car using a standard torx bit.

http://www.audizine.com/gallery/data/500/1071107102_1.jpg


Step 3:
After removing the wheel liners use a 10mm socket to remove three nuts (on each side of the car) that holds the bumper to the fenders.

http://www.audizine.com/gallery/data/500/1071107103_1.jpg


Step 4:
Remove the foglight grilles. On the underside of the bumper inside each grille opening there is a bolt that must be loosen with a 6mm hex key socket. You do not need to back out these bolts all the way, but only enough to release the plate that holds the bumper to the struts that hold it to the car (difficult to understand while the bumper is on the car but will become evident as you gently pull it way from the car).

http://www.audizine.com/gallery/data/500/1071107104_1.jpg


Step 5:
Pull the bumper slightly away from the car and support from beneath.

http://www.audizine.com/gallery/data/500/107105_1-med.jpg


Step 6:
On the left side of the car, behind the bumper, clamp the rubber headlight washer hose and disconnect the hose. Also in this location you must disconnect both the foglight and horn connectors.

http://www.audizine.com/gallery/data/500/1071107106_1.jpg


Step 7:

The bumper can now be removed from the car (marvel at how much surface area of the car is devoted to cooling!). You will also want to remove the righthand headlight and its base plate (torx screws) at this time as well).

http://www.audizine.com/gallery/data/500/1071107107_1.jpg

A closer view of the right side of the car showing the stock location of the smog pump that will be located to make room for the new IC.

http://www.audizine.com/gallery/data/500/1071107108_1.jpg


Step 8:
From beneath, locate the boost reservoir and remove.

http://www.audizine.com/gallery/data/500/1071107113_1.jpg

http://www.audizine.com/gallery/data/500/1071107115_1.jpg

Here's what the stock set up looks like out of the car (you will not be reinstalling this).

http://www.audizine.com/gallery/data/500/1071107114_1.jpg

Install the new bracket and smog pump in the position of the former boost reservoir.

http://www.audizine.com/gallery/data/500/1071107116_1.jpg


Step 9:
Install IC bracket and intercooler in the old smog pump location using the three bolts from the old bracket. There is not much room here so install them separately.

http://www.audizine.com/gallery/data/500/1071107117_1.jpg

http://www.audizine.com/gallery/data/500/1071107118_1.jpg


Step 10:
Here's a view from beneath with the IC installed waiting for the turbo to IC hose and IC outlet to crossover hose to be installed.

http://www.audizine.com/gallery/data/500/1071107119_1.jpg


Step 11:
Install and hook up IC hoses and diverter valve. I installed a new Forge 007 dv as part of this upgrade.

http://www.audizine.com/gallery/data/500/1071107120_1.jpg


Step 12:
Double check all hose and fastener connections. Reinstall bumper, washer connections and electrical harnesses. Reinstall foglight grilles, fender liners, and wheels. Install belly pan and lower car.

Step 13:
Road test. Check for leaks.

Step 14:
Enjoy your drive given new lower intake temps. Be happy that you are now ready for a Stage 3 upgrade!


(These instructions are for reference only. The author assumes no responsibilites for any ill-effects or negative results resulting from these procedures.)

[German Driver]

Great write up, submit it to Audiworld Tech Articles. Thanks I just saved this for my when im ready. Hopefully by waterfest 11!!!

[UltraA4John]

excellent work!

[FINA4]

Great job!

This should be definately in the DIY or Tech FAQ forum. Post it on there too, please.

[Toast]

Nice write up - wanna install mine when i get next month?

[ray-ray]

mad props dude...very nice!

[MLRA4]

That is an absolutely excellent writeup!!
Please get that over in the Audiworld Tech Articles.

Thanks,
Mike

[HyperM3]

Thank you very much for taking the time out to take the pictures and make notes along the way of the install. I know firsthand how much time it takes off the install process of whatever you are doing. Its always as a benefit for others though and you surpassed your duties. Very detailed and fantastically photographed.

May you sleep well every night lol.

[Matt Devo]

one of the best DIY guides I've seen posted...thanks for sharing

[DLSJ5]

Originally posted by Matt Devo
one of the best DIY guides I've seen posted...thanks for sharing

I concur, excellent Job!

[1/4 scale]

Originally posted by DLSJ5
I concur, excellent Job!

Hey Drew, thanks again for that hose! Couldn't have completed the job without it. [:D] Now I'm ready for your stage 3.

[DLSJ5]

Originally posted by 1/4 scale
Hey Drew, thanks again for that hose! Couldn't have completed the job without it. [:D] Now I'm ready for your stage 3.

haha, no doubt it's good stuff. You asked me a question in your old post about the Duals, with regards to where I got the smog pump hose, I got it from a Audi Dealer in London, in fact you can get the whole kit from them, not sure if it's cheaper than the GS kit. Good luck with your ride Bro!

[Tim0s002]

what a wonderful contribution [hail]

This should be saved here as well as audiworld.

[fongaroos]

DAYAM!

thanx so much. please be sure to keep the pics up as well. so many times ive looked up old DIYs and the pics are all gone. having the pics helps SOOOO MUCH!

THANX FOR THE GREAT WRITEUP!!!

[JPinSF]

Awesome info! Thanks for the write-up!

[1/4 scale]

Thanks for the encouragement guys. At your request I submitted this as a DIY How-To. Hopefully it will be up and running soon. I'll keep the pics alive on this thread until then.

[wrench]

[b6usp]

Very nice write up. When you attempt your next big project I hope you do a write up on it as well. Truly, one of the best I've seen. Thanks.

[Saturnine]

What kind of jack stands are those?? [eek][eek]

http://www.audizine.com/gallery/data/500/1071107101_1.jpg

[:D]

Nice work thou, maybe this should be added to the DIY forum...

[i_eat_staples]

that write up is so good i could probably install the damn thing on my s4

[wiszmaster]

this is a def. needed mod for anybody that is chipped, and lives anywhere south of canada ;-) ... especially in the summer.

[1/4 scale]

Originally posted by Saturnine
What kind of jack stands are those?? [eek][eek]



ROTFL! You don't like my hillbilly jack stands! You must be from SoCal. Heck this is "Boss Hogg country." [race]

Seriously, these are pretty safe (how much does your house weight?!) and gentle on suspension points. I need to get either a larger floor jack or shorter stands (the ones I normally use are just too high, even at their lowest setting).

[Quatime]

Nice write up and I still tip my hat to you for painting the Projektzwo front lip matte grey to match the sides! Amazing idea!

[Bossman]

Someone please stick this to DIY How-To's section

[Laurentiu]

Bumping this thread after years. I did the retrofit following this tutorial, now I see a 0.2bar (2.9psi) pressure drop in the intake. Is that normal or do I have a leak? I don't know if the temperature drop compensated for the pressure drop...

[MetalMan]

Did you pressure test the system? That would be a good place to start. I would expect to see a little pressure drop from the 2nd intercooler and additional piping, but 2.9psi seems a lot.

[Laurentiu]

Should I plug the system (starting right after the turbo and ending at the throttle valve), pressurise it, leave it a few hours and then check the pressure? Or any other idea of how to pressure test the system?

[Luxury]

I love the looks of this and want to do it. Any suggestions on where I can find these components? I’ve gone to the dealer to get ETKA screenshots and parts list but finding the proper items seems near impossible.


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[arazvan2002]

You should consider to buy parts from scrap yard, eBay, etc. If it is to buy new original parts, then there are better solutions with better efficiency at the same or less money.

[Luxury]

There is no way I’ll be using new parts. I could swap it for the cost of new Intercooler parts. These parts are rare, as of right now I am chasing the end of the rainbow. I have been in contact with some Brits, time will tell.


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[grayjay]

Original post was from 2005, since then the USA market B7 had stock DSMICs. The B7 right side intercooler can be adapted to a B6 and is much easier to source than finding 15 year old euro only parts.

[Gosser]

Any B7 2.0 in north America will work, dont bother with the overseas stuff:
https://www.audizine.com/forum/showthread.php/803714-B7-Passenger-Side-Intercooler-DIY
There are sooooooooo many B6s and B7s in the junk yards right now, I think mine has a dozen b6 and b7s. Nobody grabs these parts. If you cant find them in the yards, hit up ebay. Its cheaper to pull them your self, and you can grab all the little brackets and bolts too.

Incase you were considering the B7 driver side IC, it doesnt fit all that well and I would avoid it all together:
https://www.audizine.com/forum/showthread.php/797905-b6-vs-b7-intercooler

[oaybar007]

There is no way I’ll be using new parts. I could swap it for the cost of new Intercooler parts. These parts are rare, as of right now I am chasing the end of the rainbow. I have been in contact with some Brits, time will tell.


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I had bookmarked this thread and your reply years ago as I, too, was looking for these parts forever. Impossible to find here in the US, unfortunately. I finally found someone in the EU who was nice enough to source all the parts for me and export them. He asked if anyone else needed this set up and I figured I would chime in. I'm happy to try to help anyone out still looking. I know how frustrating it is, but the parts are out there. They are just all in Europe!

[AvantNoir]

I had bookmarked this thread and your reply years ago as I, too, was looking for these parts forever. Impossible to find here in the US, unfortunately. I finally found someone in the EU who was nice enough to source all the parts for me and export them. He asked if anyone else needed this set up and I figured I would chime in. I'm happy to try to help anyone out still looking. I know how frustrating it is, but the parts are out there. They are just all in Europe!

Curious what it cost to import everything from Europe?
Tons of B7's in the junkyards here in SoCal. Less than $150 for the parts.

[oaybar007]

Curious what it cost to import everything from Europe?
Tons of B7's in the junkyards here in SoCal. Less than $150 for the parts.

It was about $350. Not bad for someone to find, pull, clean, package and ship. I also paid more because they thought I needed the smog pump too, so they included it. It was already packed so I was fine paying for it.

From what I understand the B7 passenger side isn't plug and play, but others have made it work without too much trouble. Not a bad option. For me with the BEX setup, it became such an elusive part that I just wasn't going to be happy until I had found it. It was more about the chase ;)

[Luxury]

I had bookmarked this thread and your reply years ago as I, too, was looking for these parts forever. Impossible to find here in the US, unfortunately. I finally found someone in the EU who was nice enough to source all the parts for me and export them. He asked if anyone else needed this set up and I figured I would chime in. I'm happy to try to help anyone out still looking. I know how frustrating it is, but the parts are out there. They are just all in Europe!

My cost was similar. Double that in hours of research. Hobbies, I suppose. I’m glad you found a setup yourself!