www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2014 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You



Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKVI-A6 Golf family including Jetta SportWagen (~ 2010-2014)

VW MKVI-A6 Golf family including Jetta SportWagen (~ 2010-2014) Discussions area for A6/MkVI (2010-2014) Golf and Golf Wagons (Jetta Sportwagon in the USA).

Reply
 
Thread Tools
Old April 7th, 2012, 08:17   #1
Thorny
Member
 
Join Date: Jun 2011
Location: Colorado
Fuel Economy: 42 mixed
Default How do I protect my intercooler?

I was looking at the lower portion of my radiator the other day, which is the intercooler, right? Anyways, I've got 42K miles on my 2011 JSW now and I'd say that approximately 70% of the fins on the front of the intercooler are bent over from being hit by rocks and pebbles off the road here in Colorado.

What, if anything, are you guys doing to protect the fins of the intercooler to protect it and maintain good airflow?

And now that mine is all bent over, is there anything that I can do to re-establish good airflow?
__________________
2011 Candy White JSW 6M

Thorny is offline   Reply With Quote
Old April 7th, 2012, 08:35   #2
JSWTDI09
Veteran Member
 
JSWTDI09's Avatar
 
Join Date: Jan 2009
Location: Las Vegas, Nevada
Default

Your intercooler is not the bottom portion of your radiator. There are three separate parts stacked together in a kind of sandwich. IIRC, your radiator is in front, your intercooler is behind that, and your AC condenser is behind that. I'm pretty sure that I got them in the right order, but I could be wrong. You can follow the tubes and lines to verify. I know I am right in that they are 3 components sandwiched together and they are all similar in size. I think you are seeing bent fins on your radiator only.

Have Fun!

Don
__________________
2009 Jetta SportWagen TDI
Candy White/Anthracite; Build date: 01/16/09; Buy date: 02/09/09
Coveted Three Pedal Version, Big hole in roof
Dieselgeek Shortshifter & Panzer Plate (my favorite & my smartest mods)
2MicronTech Pure Flow and Contain Flow CR fuel system modifications

Last edited by JSWTDI09; April 7th, 2012 at 08:57.
JSWTDI09 is offline   Reply With Quote
Old April 7th, 2012, 08:35   #3
Jack Frost
Veteran Member
 
Jack Frost's Avatar
 
Join Date: Nov 2007
Location: Rural Manitoba
Default

My car has a bra on the front to protect it from flying gravel. The bra has a piece of guaze that covers the intercooler intake.

I also slow down a lot when I see someone coming the other way on a gravel road. That reduces the impact of any flying stones a lot. Theoetically by about 1/4 of what it could be. So far, no physical damage at all after about 17,000 km of gravel roads.

As for repairing the damage. I know that a comb-like device is used to straighten out cooling fins of air exchangers, but looking at the intercooler just now, it seems that might be tricky and you would have to probably remove it to do something as finicky as that.
__________________
2009 TDI, Spice Red with Black Interior, DSG, Purelli Winter Tires, VW Block Heater
1996 Suburu Legacy (wife)
John Deere 2130 Diesel Tractor
1989 Ford Mustang 5.0 (gone but not forgotton)
Jack Frost is offline   Reply With Quote
Old April 7th, 2012, 08:55   #4
Rutch
Veteran Member
 
Join Date: Jun 2011
Location: Seneca Falls, NY
TDI(s): 2011 JSW TDI
Default

Quote:
Originally Posted by JSWTDI09 View Post
Your intercooler is not the bottom portion of your radiator. There are three separate parts stacked together in a kind of sandwich. IIRC, your radiator is in front, your intercooler is behind that, and your AC condenser is behind that. I'm pretty sure that I got them in the right order, but I could be wrong. You can follow the tubes and line to verify. I know I am right in that they are 3 components sandwiched together and they are all similar in size. I think you are seeing bent fins on your radiator only.
They're definitely sandwiched together, but I think the AC condenser is up front and the radiator is in the rear. Hoses coming off the one closest to the engine are too big to be AC lines and too small to be charge pipes. Either way the intercooler is in the middle.

Unless a rock goes all the way though the AC condenser or backwards through the radiator, the intercooler is pretty well protected from the factory.
Rutch is offline   Reply With Quote
Old April 7th, 2012, 09:00   #5
Thorny
Member
 
Join Date: Jun 2011
Location: Colorado
Fuel Economy: 42 mixed
Default

Thanks for the clarification.

My concern is still airflow. If the fins are all bent over on the front section, how much airflow am I loosing to it and the cooling devices behind it?
__________________
2011 Candy White JSW 6M

Thorny is offline   Reply With Quote
Old April 7th, 2012, 09:15   #6
JSWTDI09
Veteran Member
 
JSWTDI09's Avatar
 
Join Date: Jan 2009
Location: Las Vegas, Nevada
Default

Quote:
Originally Posted by Thorny View Post
Thanks for the clarification.

My concern is still airflow. If the fins are all bent over on the front section, how much airflow am I loosing to it and the cooling devices behind it?
How much air flow is effected depends on how many openings have been closed off. It would be possible to put a piece of screen in behind your grill, but this might have to regularly cleaned and/or replaced. Then the question becomes: how much airflow is reduced by the screen? I do not have an answer for this question.

Have Fun!

Don
__________________
2009 Jetta SportWagen TDI
Candy White/Anthracite; Build date: 01/16/09; Buy date: 02/09/09
Coveted Three Pedal Version, Big hole in roof
Dieselgeek Shortshifter & Panzer Plate (my favorite & my smartest mods)
2MicronTech Pure Flow and Contain Flow CR fuel system modifications
JSWTDI09 is offline   Reply With Quote
Old April 7th, 2012, 09:16   #7
Jack Frost
Veteran Member
 
Jack Frost's Avatar
 
Join Date: Nov 2007
Location: Rural Manitoba
Default

I wouldnt worry too much about air flow. The diesel motors seem impossible to overheat. During the winter, I am always blocking the air flow to keep the engine at its operating temperature.

The biggest impact to your airflow is that during the summer, the air conditioner would be compromised, and to a lesser extent, the intercooler would not be as effective. During the winter, there are no issues as far as I can determine.
__________________
2009 TDI, Spice Red with Black Interior, DSG, Purelli Winter Tires, VW Block Heater
1996 Suburu Legacy (wife)
John Deere 2130 Diesel Tractor
1989 Ford Mustang 5.0 (gone but not forgotton)
Jack Frost is offline   Reply With Quote
Old April 7th, 2012, 09:56   #8
Cogen Man
Veteran Member
 
Cogen Man's Avatar
 
Join Date: Jun 2011
Location: Kingston, Ontario, Canada
Fuel Economy: Better than the Toyota FJCruiser
Default

To give any general answer we would need to see a pic of the offending component. The fins are a means to increase the surface area for maximum cooling. A picture would help but might not be possible. I'd say if anymore than 1/4 of the fins are bent then you may need to do something about it.
__________________
Cogen Man is offline   Reply With Quote
Old April 8th, 2012, 13:13   #9
sgoldste01
Veteran Member
 
Join Date: Mar 2010
Location: Webster, NY
Default

Perhaps one solution would be to stop tailgating? If your intercooler fins are bent badly due to rocks, I'm guessing your bumper and hood must be badly dinged too....
__________________
SOLD: 2010 Golf 4-door TDI with 30k on odometer.
BOUGHT: 2012 Subaru Impreza Sport Premium 5-door with manual tranny.
sgoldste01 is offline   Reply With Quote
Old April 8th, 2012, 17:57   #10
Thorny
Member
 
Join Date: Jun 2011
Location: Colorado
Fuel Economy: 42 mixed
Default

Quote:
Originally Posted by sgoldste01 View Post
Perhaps one solution would be to stop tailgating? If your intercooler fins are bent badly due to rocks, I'm guessing your bumper and hood must be badly dinged too....
Here in Colorado on the interstate where I spend 95% of my 40K miles you either ride close the car in front or you get cut off constantly. When I can I leave lots of room. The front bumper is getting pelted too, but I put a clear bra on the hood so it's in good shape.

Here's an image of the radiator, you can see the damage as well as the upper portion where it's protected from road debris.

__________________
2011 Candy White JSW 6M

Thorny is offline   Reply With Quote
Old April 9th, 2012, 05:20   #11
740GLE
Veteran Member
 
Join Date: Aug 2009
Location: NH
Default

I don't think a little window screen hardware cloth behind the grill will really dampen the air flow through the sandwhiched components, and it'll only help deflect some of that stuff, won't solve all your issues though.

Could you pull the bumper, use a garden hose clean some of that crap out then use a fin straithener on some of them?
__________________
His: 2010 Sedan, cog swapper, build date 07/09
Hers: 2012 Passat, Roof+Nav, build date 05/12

"Whole new generation Passat will work with you to create outstanding new classic, defining a new pattern!"
740GLE is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Protect Golf from dogs? crazyjo Upgrades (non TDI Engine related) 24 November 11th, 2006 13:21
Serve and protect my *** darkscout General Automotive 33 July 26th, 2006 07:21
Anyone protect their TDI from cavitation? Westro VW MKIV-A4 TDIs (VE and PD) 2 November 26th, 2003 13:37
Does this protect your turbo? psyick VW MKIV-A4 TDIs (VE and PD) 5 May 3rd, 2002 05:41
Protect your oil sump? msauve Upgrades (non TDI Engine related) 9 October 27th, 2000 09:53


All times are GMT -7. The time now is 03:40.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2014
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2013, All Rights Reserved
Page generated in 0.39899 seconds with 10 queries
[Output: 105.34 Kb. compressed to 89.00 Kb. by saving 16.33 Kb. (15.51%)]