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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old June 17th, 2011, 08:44   #1
Rudy 'D'
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Default Intercooler upgrade

I have an '04 Golf TDI (BEW) that is currently stock. I am planning on a turbo upgrade to a VNT 17/22.

Do I need a larger/better intercooler? If so, Which one?

Thanks.
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Old June 17th, 2011, 11:15   #2
LNXGUY
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Do you need one? No.. You've got a few more things to upgrade until you get to the IC..
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Old June 17th, 2011, 13:24   #3
Jump.Wire
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IC upgrade should be one of the last things on your mind. Upgrade to a turbo back exhaust first.
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Old June 17th, 2011, 18:04   #4
FlyTDI Guy
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Basically it goes like this...

Add more fuel until you smoke (Nozzles)
Add more air to clear it up (Turbo)
Replace your clutch because it's now smoked.
Add more fuel as needed.
Upgrade DP, exhaust, IC & piping.
Start obsessing about a GTBxxxx

Let me amend this a bit...

for your BEW it's more like

Tune
Turbo
Clutch
Exhaust/IC
More fuel (Bigger injectors)
Re-Tune
Now obsess about huge turbo, rods, LSD, ported head, even bigger injectors...
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Last edited by FlyTDI Guy; June 17th, 2011 at 22:00.
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Old June 19th, 2011, 15:40   #5
Richard55
 
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I love this progression chart lol

Quote:
Originally Posted by FlyTDI Guy View Post
Basically it goes like this...

Add more fuel until you smoke (Nozzles)
Add more air to clear it up (Turbo)
Replace your clutch because it's now smoked.
Add more fuel as needed.
Upgrade DP, exhaust, IC & piping.
Start obsessing about a GTBxxxx

Let me amend this a bit...

for your BEW it's more like

Tune
Turbo
Clutch
Exhaust/IC
More fuel (Bigger injectors)
Re-Tune
Now obsess about huge turbo, rods, LSD, ported head, even bigger injectors...
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Old June 19th, 2011, 17:04   #6
dieseleux
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Quote:
Originally Posted by Richard55 View Post
I love this progression chart lol
Me too!
+1




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Old June 19th, 2011, 17:30   #7
Rudy 'D'
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Join Date: Mar 2010
Location: Right here in Alabama!
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Quote:
Originally Posted by FlyTDI Guy View Post
Basically it goes like this...

Add more fuel until you smoke (Nozzles)
Add more air to clear it up (Turbo)
Replace your clutch because it's now smoked.
Add more fuel as needed.
Upgrade DP, exhaust, IC & piping.
Start obsessing about a GTBxxxx

Let me amend this a bit...

for your BEW it's more like

Tune
Turbo
Clutch
Exhaust/IC
More fuel (Bigger injectors)
Re-Tune
Now obsess about huge turbo, rods, LSD, ported head, even bigger injectors...

Thanks for the advice.
Seems like everyone thinks the stock BEW (PD) injectors are big enough for mild mods.

You guys rock. Thanks again.
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Old June 21st, 2011, 18:27   #8
darkhorse
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Quote:
Originally Posted by Rudy 'D' View Post
Thanks for the advice.
Seems like everyone thinks the stock BEW (PD) injectors are big enough for mild mods.

You guys rock. Thanks again.
They can easily get you to 150hp & a bit beyond.
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Old June 23rd, 2011, 04:02   #9
coalminer16
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Fuel Economy: as good as 58 (over 700 miles) and as low as 30 over the same route
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You are a ways from needing injectors yes. But I am still interested in the whole intercooler question as there isn't many options for the PD engine that is bolt on. I am interested due to the trailer towing and seeing the intake temps from the scan gauge rise a lot.
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I really had no idea that VW dealerships were so awful to go to, they sound like undertakers cos everything that goes in there winds up dead.
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Old June 23rd, 2011, 04:58   #10
milehighassassin
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Towing a trailer will kill your intake temps. I have a Eurojet SMIC and it does a great job until I put a heavy load on it with the trailer.
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Old June 23rd, 2011, 05:56   #11
coalminer16
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Fuel Economy: as good as 58 (over 700 miles) and as low as 30 over the same route
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I bought this spring the vented fender liner as my OEM one was cracked up some anyways. It helped a little but still would like a better intercooler for the PD.
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1981 Rabbit car-4 door, 1.9 TD aaz, 5 spd
1981 Caddy VW truck-Topper with it
2004 Golf-2 inch lift, Q-loader stage 1 tune
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Quote:
Originally Posted by rmchambers
I really had no idea that VW dealerships were so awful to go to, they sound like undertakers cos everything that goes in there winds up dead.
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Old June 24th, 2011, 12:15   #12
VWBeamer
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If it fits a MKIV ALH, it will fit a PD with little trouble, in fact it's almost the same if you run a 17/22.

Only real difference is where it joins the intake.
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Old June 24th, 2011, 12:26   #13
diesel-dave
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Plug in a scan guage, drive around and monitor your air intake temps
This will tell you if your intercooler is good enough

Again you live in the south
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