Hello all though this would be nice to share. Now I recently registered on this forum however I have been all over this and other forums for years. I register with this one because in simplest terms I like it. Though this something I could share. Well from searching the many forums I know that there is a big split between dudes with side mounts vs front mount intercoolers. Well I was at that cross road for months. This was my dilemma I wanted to upgrade my intercooler but want to keep the stock b6 look so a front mount was out the question. So that’s when I started my search. I was excited when I found that there was a Euro b6 that came with a dsmic. Did my research which brought me to ¼ Scale Thread: B6 A4 Dual Intercooler Installation http://www.audizine.com/forum/showth...r-Installation. I started searching for the parts to put the kit together which was easier said than done (FAILED and wasted money). After reading a bunch of threads titled dsmic vs fmic I decided to go front mount. Was not very happy but need more cooling capability because I was going to upgrade my turbo. I started researching for the best FMIC for my audi b6. Found a bunch of threads that spoke about those too. I decide to go with the ER a4 b6 sport series FMIC http://evolutionracewerks.com/node/60 which fits behind the stock bumper with little to no modification as stated by ER. However the price was high. Though about getting a cheap kit from ebay but the reviews were too mixed. I just want something good. My friend who has a b7 a4 got into an accident and his car was in another friends body shop. When there to look at it and that’s when I notice the b6 & b7 chassis is the same so I though could the intercoolers work. Once again i started to do the research. Did not find much about anyone doing that install and the one thing I found was a dude sell a setup he had on his b6 to go fmic I believe https://www.panjo.com/buy/oem-dual-i...3#&gid=1&pid=1 . So that was not very encouraging. Back to the ER site I was looking at the fmic. I had it I my shopping chart and was one click away, however could not bring myself to make the purchase (LoL). Started looking at just updated my smic but the selection was very small for the b6. Was about to buy the TyrolSport UG SMIC Intercooler for Audi B6 A4 1.8T http://www.tyrolsport.com/b6intercooler but 800 for smic couldn’t do it. I don’t know if anyone else notice that the ER FMIC is everywhere you search couldn’t escape it. I was about to buy the Apikol SMIC http://www.apikol.com/index.php/prod...2002-2005.html and my friend was like just get the front mount and get it over with. I was like hell no! Need less to say I did not get the Apikol smic. After getting pass December 2015 I was back on the search again and more determine to DSMIC. It just so happen a came across Modbargins http://www.modbargains.com/ they had a tax sale that’s when I took a look at Evolution Racewerks Side Mount Intercoolers for 2006-08 Audi A4 [B7] 2.0T AU-SMIC002 which almost the same price as the Tyrosport b6 SMIC and a 100$ less than ER (still is) plus I got 50$ off http://www.modbargains.com/Evolution...Audi-B7-A4.htm . I got them quick but had to wait almost a month to get them. Dudes at modbargin was great I called like every week for updates. Got the intercoolers in April or may 2016 they’re huge which made me a bit worried about fitment. But everything fit great. If you look at the specs you will see these intercoolers have a Whopping Total of 657ci of core volume which is 306ci more than the ER A4(B6) sport FMIC and only 3ci less than the ER A4 (B6) Competition Series FMIC.
Now ER Audi A4 B7 Intercooler installed on Audi B6
The install was not too bad it only took me about 2 days to install the intercoolers. Can be done in a few hours if u have all
u need. Attempt at your own risk.
Parts Need:
1. Evolution Racewerks Side Mount Intercoolers for 2006-08 Audi A4 [B7] 2.0T AU-SMIC002
2. AUDI A4 B7 2.0 – Lower core support bracket 8E0199521DF http://www.ebay.com/itm/2002-2003-20...item3d1f40a2f6
3. Audi intercooler hose set A4 b7 2.0 turbo silicone http://www.ebay.com/itm/111331855410
4. Secondary air bracket 3D0 906 515B (optional)
5. From Autozone hose 87840 (optional)
6. B7 driver side intercooler bracket.
7. 6 inch 3/4 metal pipe
8. B7 right side intercooler shroud
If I forgot anything got tons of pictures
1. Remove bumper and rad support (DO NOT OPEN AC SYSTEM) allow AC condenser to rest in a safe position and try not to step on it.
2. Remove intercooler and mounting bracket
Comparing stock to ER intercooler
3. Install b7 bracket with mounting plate that came with intercooler
This is where my 1st issue came about’ the b7 intercooler sits at an angle. The washer tank is in the way. To solve the problem straighten the mounting arm on the driver side intercooler. This will allow the intercooler mounting arm to sit flat on the bracket. This will also solve another problem of the headlight fitting. Due to the change in angle of the arm I had to drill the holes bigger and drill a third one for proper mounting so in could secure the intercooler properly.
By straighten the arm I cause another problem the intercooler does not secure in the mount at the bottom.
Problem solved. I drilled and tap the intercooler so I could bolt a bracket to it. Found a metal (wish I had a piece of aluminum) arm bent it to the desired position. With a few nuts and bolts problem solved.
Driver side intercooler is installed
Note my intercooler to throttle hose look like this because I’m using a 70mm throttle not the stock 60. You can use your stock hose. You will need the b7 intercooler hose to connect the intercooler to the radiator support crossover tube.
Now the passenger side. Remove the secondary air pump and bracket. Try not to damage the connecting hose u will need them later. If u install the intercooler as is you will notice the AC hose is a problem. Easy fix is to flatting out the mounting arm (somewhat trial and error) which make it move away from the ac hose (just don’t damage the intercooler). Also drill the hole out bigger will need to move it a little. Bolt up and intercooler is install. Couple things to keep in mind make sure u cover up and insulate the shape edges. The intercooler kit comes with a few pads make sure you use them. Now the hose coming from the turbo became a problem later on when I install the Radiator Support Cross Tube. It was in the way. I had to use a short 90 degree that I got in this kit http://www.ebay.com/itm/Silicone-Int...ZSupuZ&vxp=mtr with a 2.25” pipe n 4-6” long with part of the turbo hose from this same kit. Note picture with final revision is with the secondary air pump picture. I think the hose from the b7 kit will help too.
Now comes the fun part. I made my own secondary air pump bracket from one from a b5 1.8t I think that’s were its from, the part # is 3D0 906 515B. Like I said it’s optional. You can find the correct bracket of make your own. I cut the mount formed it the way I want and drill holes to mount it to the block. The bolts holes are already there I just had to clean the threads. The connector is long enough to reach.
Now the hoses. I reuse the original hoses. I was able to configure the short hose to fit. The long hose that comes of the air box I had to modify. That where the hose from AutoZone comes into play. The hose was ideal because one end was bigger. I used rtv to seal the hose and clamps to hold in place.
Moving on now the Radiator Support Cross Tube. After a close look I notice the only difference between the b7 and b6 is the curve on the right side.
Now being that we eliminated that accumulator that the secondary air pump took the place of , I need somewhere/ somehow to connect my blow off valve. What I did was drill a hole in the cross tube and weld the 6” 3/4 pipe to it.
I had to cut about 3” off the pipe once I figured out where I want to position my diverter valve. I use a 1.5ft long 1 inch hose with the 90 degree elbow ( part # 06B133989C) to reach my dv. The vacuum hose to the dv is long enough to reach. Now it is time to install the radiator support but you will have to make some slight modification. See picture. You will have to make cut out to clear the top of the intercoolers
The left intercooler shrout is the same one from the b6 no mod need I just used a screw that is supplied with the intercoolers. The right side one is from the Euro b6 with the dsmic but u can use one from the b7 just have to cut to fit.
Final Results
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