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View Full Version : comprehensive diy ebay intercooler install on a 2001 a4



p24rick
11-22-2010, 10:31 PM
just installed my new front mount on a 2001 a4, which was a pain mainly because of the secondary air injection (smog pump) but I have alot of pictures, and i will list a comprehensive guide on how i did mine because I had a hard time finding good info on relocating the s.a.i, diverter placement, map sensor, ect.

parts used; ebay core, 2x1 silicone T, 2" 90, (2) 2-1/4 45 bends, 2-1/2 45 and 75 bends, map adapter flange, (2) 2-1/4 couplers, (2) 2-1/2 couplers, stock 2x2-1/4 90 bend from smic, (2) angle brackets.

for most that have researched this, ill assume everyone can figure out taking everything apart. once the bumper and headlights are off, and the factory intercooler is removed, the hardest part is working around the s.a.i pump, on a 2001 it seems the only logical way is relocation. I started out by removing the pump and the bracket. then cut off half the bracket to reinstall to support the ac canister
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-17162620.jpg
then the easiest place to relocate the pump to was underneath the intake (where the factory airbox used to be)
so i screwed the remainder of my bracket to the frame with self taping screws
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-17183830.jpg
then install the pump into the bracket, but i did have to shorten the inlet hose to the pump to connect everything
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-17184201.jpg
most people dont, but i removed the metal bumper from the cover and mounted the core to it with 90 brackets
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-18191921.jpg
the power steering tubing and ambient air sensor can be relocated slightly lower by drilling a hole in between the two tubes and remounting to the same location, i just used zip ties on the sensor
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-18193708.jpg
i didnt want the factory diverter plumbing so i just used a 2"x1"silicone T strait to the turbo w/ a 2" 90
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-17174520.jpg
then the factory hose on the bottom of the side mount got reused here going to the 2-1/4 45
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-17234622.jpg
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-18191826.jpg
that completes the hot side, after fitting the cold side up, i had it welded by a local welder
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-18181937.jpg
and yes i know my couplers are different colors, i got some for free, lol
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-18191754.jpg
keep in mind i did trim the plastic framing on both sides
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-18192004.jpg
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-19142112.jpg
now because of what i did to the bumper, getting it back on was the hardest part. i dont know how some guys get these to fit so well. my core was only 2-1/2" but i had to hack most of the bumper just to get a almost decent fit. its hard to tell but the lower lip is mostly held on by zip ties on the inside, there really isnt much left.
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-19132345.jpg
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-19154037.jpg
then trimmed up the parts in the bay a bit
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-19155852.jpg
then after a testdrive i blew a hose off and had to ghetto bead my pipes by grinding a groove into a vise clamp and hand grooving some beads
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-19125259.jpg
completed and holding strong!
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-21122657.jpg
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-21122807.jpg
[drive]

yuriy
11-23-2010, 08:00 AM
haha for the past couple of days ive been looking all over for diy's because I'm gonna grab this kit http://cgi.ebay.ca/CXRacing-2-25-Turbo-Piping-Kit-28x7x2-5-Intercooler-/190468675173?pt=Motors_Car_Truck_Parts_Accessories&hash=item2c58d15665
What were the dimensions for your intercooler? Also, did you you buy the bung for the map sensor seperately and have it welded on, or was it made by the exhaust place?

biketsai
11-23-2010, 08:24 AM
Nice, can you elaborate on how you did a ghetto bead job? Im sure many people would be interested in knowing this too.

thenj3
11-23-2010, 10:39 AM
How much did your welderr charge you to weld the map flange on? Nice write up though. I'm debating whether or not to delete the sai when I do my front mount

juxsa
11-23-2010, 11:40 AM
Also, another trick is to use hairspray. Spray the ends of the pipes where the couplers slide on with aquanet and it acts as a lubricant to make it easy to slide them on and a few minutes later it acts like glue.

p24rick
11-23-2010, 06:47 PM
How much did your welderr charge you to weld the map flange on? Nice write up though. I'm debating whether or not to delete the sai when I do my front mount welder charged $40 for two welds, was a pretty good deal actually.

p24rick
11-23-2010, 07:00 PM
diy ghetto bead; on the C clamp i grinded a groove in one end and a point on the other so that when it is compressed the two fit together, on in the other. now this only seemed to work on thinner wall pipe because you need a bit of clamping force. i had to use a wrench as a small cheater to get enough force. start in one spot and with the point side of the clamp inside the pipe and compress the clamp to create a small dent in the pipe. then repeat all the way around until you have a bead all the way around.
http://i236.photobucket.com/albums/ff247/p24rick/cars/2010-11-19123214.jpg
but i hear hairspray also works well too.

p24rick
11-23-2010, 07:10 PM
haha for the past couple of days ive been looking all over for diy's because I'm gonna grab this kit http://cgi.ebay.ca/CXRacing-2-25-Turbo-Piping-Kit-28x7x2-5-Intercooler-/190468675173?pt=Motors_Car_Truck_Parts_Accessories&hash=item2c58d15665
What were the dimensions for your intercooler? Also, did you you buy the bung for the map sensor seperately and have it welded on, or was it made by the exhaust place?

sensor adapter and intercooler were off ebay. sensor adapter= $16 ,intercooler (27.25” x 5.5” x 2.5”)= $75

CamrideA4
03-12-2011, 07:59 AM
I just wanted to say thanks to the OP for this thread, it has helped me out a ton. I'm currently figuring out everything I need to order for my FMIC setup and I was wondering where you got the silicone T for the diverter valve? The only ones I've found on eBay are $30 shipped which seems a bit steep for that tiny piece.