DIY: Protection screen for intercooling radiator

**Dasquade** · 08-17-2011 05:07 AM

When i installed my FMIC i also added the hardware cloth (inox -> but painted it black) from my local DIY shop. Paid around 20€ if not mistaken for the mesh. Happy i did it, can almost not see it, but feels better knowing the intercooler and AC is somewhat better protected.

**Kandiru** · 08-17-2011 12:28 PM

Upper+Lower+L-Foglight Grille Protection Screens Done
===================================

Kudos to Patinsd for leading the way, by far the nicest looking
and easiest to work with mesh material IMHO.
Materials:

1. Customcargrills.com "Small Diamond Grill Mesh Sheet" 12x48" and a 6x36"
along with 20ft run of "Neoprene Rubber Edge Trim"
2. Steel wire chrome plated.

Tools: Torx kit 27 and 10 used
Fiskars thin metal snips

I just removed the front cover with the 4 Torx 27 bolts, then undid the two top
grille retainer allowing it to slide out 1".

Lower intercooler grille: 12x48" was cut with 1" redundancy to allow tensioning in the natural
well between the intercooler and grille, i just dropped the tape into the well and measured.
Then applied edge trim to bottom and sides, that is after i primed and repainted the
cut line. The top however was still wobbly, so i used steel wire to tie it to the wide center
downward facing plastic tab resting on the solid structural beam, had to tension it a bit
with a V bend before i slid it under and tied the ends, as the bottom of the plastic tab just
rests on that beam.

Top radiator grille: 6x36" used. Removed homelink and holder, removed the 4 light alu
screws on the back of edges of grille, then measured at the top and cut again with 1"
redundancy. Then i made 1" wide by 2.5" deep cutouts on both bottom corners. Then
dropped the cover in tight, tight to the back of grille, no edge trim here, as everything
sits on plastics. Then used brute force to bend the top so the mesh sits flush with grille
and allow Homelink over it. Put everything back over the grille, now held in place by 7 screws.

Left fog grille radiator: used leftovers. Cut about 9" tall piece, as long it took to reach the foglight,
covered the entire thing in edge trim, the Houdinied it through the top slit of the grille, and used a
hook i created to pull the foglight edge while i was pushing from the left. Wasted a piece, did another
one, beauty of aluminum is that it bends very easily, in the end it looks super cool. The trick is for it
to end up resting tight with a nice backward curve wedged between the medial wall of the grille and
foglight.

Tip: no matter how carried away you get, do not touch the radiator fins, they will bend very easily.

Took me 8-11PM.

Many thanks to Patinsd and the other pioneers without whose ideas i would have surely failed.

The following may look fugly frontally but perfect without a flash illuminating the grille well:

**PsYkHoTiK** · 08-17-2011 12:44 PM

I really need to do the lower opening by the fog light. Could you go back into detail on how exactly did you fix it on? Did you use adhesive?

Thanks!

**richib86** · 08-17-2011 07:35 PM

this is something that eurotech built for me

. ill post more pics of the top and bottom, its built as two separate parts that bolt to the cross beam

**NWS4Guy** · 08-17-2011 09:48 PM

Nice setup to protect that new HE there Rich!

**patinsd** · 08-18-2011 09:45 AM

I do not have picture of the lower opening behind the fog light but I used the same material left over from the middle gril .I did not cover the all surface of the opening and did not use adhesive , I just bent a piece of material in the front of the small radiator .

Originally Posted by PsYkHoTiK

I really need to do the lower opening by the fog light. Could you go back into detail on how exactly did you fix it on? Did you use adhesive?

Thanks!

**ProXy_S4** · 10-24-2011 02:53 PM

So this Grille that is on audipartssuperstore is not factory installed even though its OEM?

**NWS4Guy** · 10-24-2011 04:41 PM

Originally Posted by ProXy_S4

So this Grille that is on audipartssuperstore is not factory installed even though its OEM?

Since it is for the A7, no it's not installed on the S4, though they share the same engine and as a result, heat exchanger. It's an OEM part as it's made for the A7 - should it be on the Q7, A7, S4, S5 Cab (soon to be all S5's), Porsche Cayenne hybrid and Toureg Hybrid? Yes, they all have the 3.0 SC engine and accompanying heat exchanger.

**ProXy_S4** · 10-25-2011 08:29 AM

Awesome, thanks NWS!

Originally Posted by NWS4Guy

Since it is for the A7, no it's not installed on the S4, though they share the same engine and as a result, heat exchanger. It's an OEM part as it's made for the A7 - should it be on the Q7, A7, S4, S5 Cab (soon to be all S5's), Porsche Cayenne hybrid and Toureg Hybrid? Yes, they all have the 3.0 SC engine and accompanying heat exchanger.

**ProXy_S4** · 10-25-2011 01:01 PM

One more question, is that OEM solution a plastic grille? Just wondering as I think any decent chunk of metal or rock flying at highway speeds would go right through that if it is.

**NWS4Guy** · 10-25-2011 01:18 PM

It's a very hard and stiff plastic, likely anything large enough to crack or shatter it would still get deflected, but it would require replacement soon after to maintain any level of protection.

**NHS4** · 11-02-2011 05:49 PM

Originally Posted by helix139

1 more OEM protection screen installed here. Fairly easy install, but had to do the clips by feel from the top as my hand wont fit far enough in the lower part of the grill to align and push them in. I'm satisfied with the result though and it only took about 15 mins total, looks decent, and didn't require me to screw around with cutting mesh or screen and then trying to attach something to the grill with my Laser Interceptor heads installed and wires potentially getting in the way.

Mine arrived today. Clipped in place in just a minute or two, but just to clarify, I simply push the pins through the round holes into the fins of the radiator? It fits so well they almost don't seem necessary. Sorry for such an elementary question, but I'd hate to damage what I'm trying to protect....

**helix139** · 11-02-2011 06:22 PM

Originally Posted by NHS4

Mine arrived today. Clipped in place in just a minute or two, but just to clarify, I simply push the pins through the round holes into the fins of the radiator? It fits so well they almost don't seem necessary. Sorry for such an elementary question, but I'd hate to damage what I'm trying to protect....

Yep, that is correct. you wont damage anything

**CJ_S4** · 02-22-2012 09:32 AM

Originally Posted by helix139

Yep, that is correct. you wont damage anything

For the OEM radiator protection do we need to order 9 qty of the clips? Or does one order have 9 clips?

**helix139** · 02-22-2012 10:56 AM

order qty 9

**SierraBravo** · 02-24-2012 05:45 PM

I just ordered the OEM screen + 9 clips. With all the road work going on in my area I'm glad I found this thread. Thank you.

**Akatsuki...** · 03-10-2012 11:16 AM

Great diy and great info on the OEM protection.

But really, how often are people getting their Radiator damaged by debris? Just curious, and no offence to OP or anyone else here, but is this one of those things ppl overly worry about over the internet? or does it actually happen often? Just want to know since my car will be here shortly.

**DUBSPORTN** · 03-10-2012 11:27 AM

Originally Posted by richib86

this is something that eurotech built for me

. ill post more pics of the top and bottom, its built as two separate parts that bolt to the cross beam

Interested in a clean piece like that
Make more

**s4nAri** · 05-26-2012 08:27 PM

Originally Posted by tsivas27

Yes that's all you need. Oh and a torx wrench to remove the radiator cover. forgot size. I just removed the radiator cover up top.. i slid and secured the grille over the intercooler from up top access. as far as the little clips that secure the grille to the intercooler.. i accessed the small holes in the intercooler screen that they went into from the 4 slots right above the front spiltter. My hand managed to squeeze through the slots and pop them on. Make sure u wear some thin work gloves as sliding your hand through the slots can scratch u up (wrist area). I didn't try placing the clips from up top access. Probably a little more difficult.

So where do the 9 clips go with the OEM grill? Do you simply push them into the radiator screen/coils, which doesn't sound like a good idea? Does anyone have a photo? I though that they might clip at the top or the bottom but the only place that seems like they belong would actually damage the coils. Has anyone installed this OEM grill and can say where the clips belong?

Thank you

**Dasquade** · 05-27-2012 03:57 AM

Originally Posted by Akatsuki...

Great diy and great info on the OEM protection.

But really, how often are people getting their Radiator damaged by debris? Just curious, and no offence to OP or anyone else here, but is this one of those things ppl overly worry about over the internet? or does it actually happen often? Just want to know since my car will be here shortly.

It all depends a bit on where you drive and how. If you often drive on bad road with small rocks and drive close to the cars in front of you, changes are one day a rock will find its way into your intercooler or radiator.
Maybe check your hood if you are a potential victim or not :) . You can be lucky and never get hit but on the other hand, one good placed rock can cause enough damage you need a replacement.
The stock intercooler or radiator aren't that expensive, but with laybour/missing the car/etc... it might still be worth the small DIY and investment.
If you installed an aftermarket intercooler, witch most of the times comes with a much higher price, i would definatly recommand installing a protection mesh.

**PsYkHoTiK** · 05-27-2012 10:39 AM

Originally Posted by Akatsuki...

Great diy and great info on the OEM protection.

But really, how often are people getting their Radiator damaged by debris? Just curious, and no offence to OP or anyone else here, but is this one of those things ppl overly worry about over the internet? or does it actually happen often? Just want to know since my car will be here shortly.

There have been a couple of B8 S4s that "ate some rocks". You'd be surprised at how small some of the rocks were too. As for me, I have some "chips" on the paint of my mesh already. Even then, just take a look at the heat exchanger and you should see what small rocks are already doing to it. (I track the car 6-8 times a year and it goes up to the ski resort every weekend in winter)

**zulujams** · 05-27-2012 12:08 PM

Originally Posted by s4nAri

So where do the 9 clips go with the OEM grill? Do you simply push them into the radiator screen/coils, which doesn't sound like a good idea? Does anyone have a photo? I though that they might clip at the top or the bottom but the only place that seems like they belong would actually damage the coils. Has anyone installed this OEM grill and can say where the clips belong?

Thank you

The screen snaps onto the top and bottom edge of the intercooler, and the clips push between the fins. I hear you--it seems like you're going to break something. The clips slide in nicely though. The screen has some small openings where you put the clips. They run horizontally across the middle of the screen. I used some pliers to get them started (hard to reach) and then pushed them in the rest of the way by hand by reaching down from the top opening.

**Dovienya** · 07-10-2012 08:55 AM

I just installed the OEM option last night after having one losing one intercooler to this issue. The installation was even easier than expected. The only problem I ran into was caused by my huge hands not being able to get to the harder to reach pin-holes. Fortunately my wife was able to do it easily.

By the way, though this isn't covered by warranty I was able to get my insurance to cover it under comprehensive damage which for me is a $250 deductible. It still sucks but its much better than $850.

**Stereodude** · 07-10-2012 10:05 AM

What's this like for the 2013?

**NWS4Guy** · 07-10-2012 02:44 PM

Originally Posted by Stereodude

What's this like for the 2013?

Unsure yet, I have seen a couple on the street around here already, have not seen any up close while parked to inspect this though.

**CJ_S4** · 07-10-2012 03:33 PM

Originally Posted by NHS4

Mine arrived today. Clipped in place in just a minute or two, but just to clarify, I simply push the pins through the round holes into the fins of the radiator? It fits so well they almost don't seem necessary. Sorry for such an elementary question, but I'd hate to damage what I'm trying to protect....

I received my OEM protection screen months ago but opened it over the weekend. The part I got is a grille cover (no mesh) with horizontal slats about half and inch apart. The whole piece is about 5 inches tall x the width of the radiator. Pretty sure I received the wrong part. Any thoughts?

**zulujams** · 07-10-2012 05:16 PM

Originally Posted by CJ_S4

I received my OEM protection screen months ago but opened it over the weekend. The part I got is a grille cover (no mesh) with horizontal slats about half and inch apart. The whole piece is about 5 inches tall x the width of the radiator. Pretty sure I received the wrong part. Any thoughts?

The screen you bought is for the intercooler. Look down low in front of the radiator where the lower grille is mostly open. The mesh is a DIY some of us have added separately to try to protect a larger area from debris but still allow airflow.

**ENV²** · 08-01-2012 06:22 AM

Any more pics of the OEM piece? And price of it?

**wwhan** · 08-01-2012 09:18 AM

Originally Posted by ENV²

Any more pics of the OEM piece? And price of it?

Audi OEM A7 intercooler radiator grill # 8K0 820 746 C, $68.40, Tax: $5.99, Total: $74.39
Retainer clip - 3.0 liter Cooler & components, 9 ea clips # 8K0 867 646, Price: $1.74, Tax: $1.37, Qty: 9, Total: $17.03

Price was from 1.5 years ago, price is up.

One can go here if they wish; http://genuineaudiparts.com

Plenty more info on the other thread here; http://forums.audiworld.com/showpost...&postcount=161

and here; http://forums.audiworld.com/showpost.php?p=24125263&postcount=98

**Flipflops365** · 08-01-2012 10:44 AM

Originally Posted by NWS4Guy

Unsure yet, I have seen a couple on the street around here already, have not seen any up close while parked to inspect this though.

You can take a look at mine when I get it.

**ENV²** · 08-02-2012 06:42 AM

So when buying the OEM protector you also have to buy seperate clips? The part number listed for the clips, is it for the set or for just one?

EDIT: I read the whole thread.Question was answered above. Please disregard

**CJ_S4** · 08-02-2012 06:45 AM

Originally Posted by ENV²

So when buying the OEM protector you also have to buy seperate clips? The part number listed for the clips, is it for the set or for just one?

See post #94 and #95 above. Also, one thing I didn't gather by reading the thread was that the cover that shows up still needs some sort of mesh put on it to be effective. Not sure what the best method is.

**JJDubya** · 08-02-2012 06:52 AM

Originally Posted by wwhan

Audi OEM A7 intercooler radiator grill # 8K0 820 746 C, $68.40, Tax: $5.99, Total: $74.39
Retainer clip - 3.0 liter Cooler & components, 9 ea clips # 8K0 867 646, Price: $1.74, Tax: $1.37, Qty: 9, Total: $17.03

Price was from 1.5 years ago, price is up.

One can go here if they wish; http://genuineaudiparts.com

Plenty more info on the other thread here; http://forums.audiworld.com/showpost...&postcount=161

and here; http://forums.audiworld.com/showpost.php?p=24125263&postcount=98

A bit confused. Help set me straight.

1. The OEM part discussed here is for the A7 (specifically), but it also fits the S4 perfectly? (I realize they have the same engine, hence intercooler, but perhaps different grills?)

2. Does this OEM part afford sufficient protection? I realize people are also adding screen/mesh all the way to the top of the grill (covering the condenser as well?), but has anyone actually lost the condenser due to a rock strike? Since this protects the intercooler, is that sufficient to address the OPs initial write-up?

I like the OEM solution (and do agree Audi should provide this).

Thanks for the clarifications!

JW

**richib86** · 08-02-2012 07:39 AM

only reason i went with a full mesh setup is because im running the much larger APR heat exchanger which i did not want damaged

**zulujams** · 08-02-2012 07:55 AM

Originally Posted by JJDubya

A bit confused. Help set me straight.

1. The OEM part discussed here is for the A7 (specifically), but it also fits the S4 perfectly? (I realize they have the same engine, hence intercooler, but perhaps different grills?)

2. Does this OEM part afford sufficient protection? I realize people are also adding screen/mesh all the way to the top of the grill (covering the condenser as well?), but has anyone actually lost the condenser due to a rock strike? Since this protects the intercooler, is that sufficient to address the OPs initial write-up?

I like the OEM solution (and do agree Audi should provide this).

Thanks for the clarifications!

JW

The part # referenced earlier matches with the B8 S4. It may also work for the A7 but I don't know. The OEM screen is made of plastic and does have gaps in it to allow airflow. It sits directly on the face of the intercooler by snapping onto the edges and having plastic pins pushed through the intercooler fins in select spots. Is it adequate? That would depend on the size of the debris, the force of the impact, and other factors. I'm glad I put the OEM screen on, and am even happier having added the mesh. The mesh is the cheapest solution but involves a little more work cutting the piece to fit. There are large, open areas on the front of our cars. I decided to follow steps provided by others to hopefully limit or fully prevent damage to the intercooler or radiator which aren't covered by punctures according to posts by others.

**FourRingRider** · 08-02-2012 08:27 AM

I have a brand new in the box Genuine Audi Intercooler Radiator Protection Grille (Part #: 8K0 820 746 C). Retails for around $90... only asking $60 shipped! Ships fast! First to PM takes it!

Purchased it for my S4 last month and never installed it, looking to buy S6 now. The dealer won't accept returns on special order parts... my loss is your gain!

**dawei213** · 08-02-2012 09:51 AM

Originally Posted by FourRingRider

I have a brand new in the box Genuine Audi Intercooler Radiator Protection Grille (Part #: 8K0 820 746 C). Retails for around $90... only asking $60 shipped! Ships fast! First to PM takes it!

Purchased it for my S4 last month and never installed it, looking to buy S6 now. The dealer won't accept returns on special order parts... my loss is your gain!

PM sent!