Stock intercooler replacement

[2003_unicorns]

My guru has graciously informed me that the my stock Golf's intercooler has a hole in it from rubbing over the years.

I might be with epoxying if it is salvageable (I don't know exactly where it is) but wanted to get your thoughts on replacement that fits with no hassles.

I am on a set budget for this car and want to know where you got your replacement if replacement is required here.

Thanks.

 

[burpod]

this is a good one, it's fin-tube on the inside like a real intercooler. not all ebay intercoolers are that way:

Side Mount Turbo Upgrade Intercooler Fit For VW Golf/VW Jetta MK4 1.8T | eBay

VW Volkswagen Jetta GL/ GLI/ GLS Mk4 2002-2005 Year. VW Volkswagen Golf GTI Mk4 2002-2005 Year. Title: Intercooler. Direct Bolt On. Good For 350HP. bar and plate design for maximum float. Cargo transportation.

www.ebay.com

its 2.25" inlet/outlet. fits perfect if you upgrade to a 1.8t metal pancake pipe

to fit with stock you would have to use a couple 2.0" to 2.25" silicone coupler reducers

i think fcpeuro has a stock intercooler for $100, iirc by behr

many times the stock itercoolers leak from the plastic shroud rubber holes in the tubes. either that or the plastic end tanks have sprung a leak at the crimps

 

[2003_unicorns]

this is a good one, it's fin-tube on the inside like a real intercooler. not all ebay intercoolers are that way:

Side Mount Turbo Upgrade Intercooler Fit For VW Golf/VW Jetta MK4 1.8T | eBay

VW Volkswagen Jetta GL/ GLI/ GLS Mk4 2002-2005 Year. VW Volkswagen Golf GTI Mk4 2002-2005 Year. Title: Intercooler. Direct Bolt On. Good For 350HP. bar and plate design for maximum float. Cargo transportation.

www.ebay.com

its 2.25" inlet/outlet. fits perfect if you upgrade to a 1.8t metal pancake pipe

to fit with stock you would have to use a couple 2.0" to 2.25" silicone coupler reducers

i think fcpeuro has a stock intercooler for $100, iirc by behr

many times the stock itercoolers leak from the plastic shroud rubber holes in the tubes. either that or the plastic end tanks have sprung a leak at the crimps

Thanks!

 

[P2B]

My guru has graciously informed me that the my stock Golf's intercooler has a hole in it from rubbing over the years.

Not uncommon for the shroud to wear a hole in the front. I have fixed a couple with epoxy, it does work.

 

[2003_unicorns]

Not uncommon for the shroud to wear a hole in the front. I have fixed a couple with epoxy, it does work.

What type of epoxy? Regular JB weld? Thanks.

 

[P2B]

Regular JB weld?

Yup

 

[2003_unicorns]

Yup

Doesn't surprise me. Thx.

 

[454k30]

this is a good one, it's fin-tube on the inside like a real intercooler. not all ebay intercoolers are that way:

Side Mount Turbo Upgrade Intercooler Fit For VW Golf/VW Jetta MK4 1.8T | eBay

VW Volkswagen Jetta GL/ GLI/ GLS Mk4 2002-2005 Year. VW Volkswagen Golf GTI Mk4 2002-2005 Year. Title: Intercooler. Direct Bolt On. Good For 350HP. bar and plate design for maximum float. Cargo transportation.

www.ebay.com

This is the one I have. Needed to trim the inside of the bumper cover a bit to make it fit without rubbing, but nothing too drastic.

 

[BobnOH]

My guru has graciously informed me that the my stock Golf's intercooler has a hole in it from rubbing over the years.

I might be with epoxying if it is salvageable (I don't know exactly where it is) but wanted to get your thoughts on replacement that fits with no hassles.

I am on a set budget for this car and want to know where you got your replacement if replacement is required here.

Thanks.

It's underneath, if possible patch it with epoxy after getting it nice and clean.

 

[Nuje]

This is the one I have. Needed to trim the inside of the bumper cover a bit to make it fit without rubbing, but nothing too drastic.

Are the mounting tabs in the right place on this one?
Way back when I got one of these (or at least the "tacotaco" one looked the same), the tabs were slightly out and had to be "adapted" with some spacers or something in addition to trimming out some plastic on the inner side of the bumper cover.

 

[burpod]

Are the mounting tabs in the right place on this one?
Way back when I got one of these (or at least the "tacotaco" one looked the same), the tabs were slightly out and had to be "adapted" with some spacers or something in addition to trimming out some plastic on the inner side of the bumper cover.

i think they can be all slightly different. but it will fit with some futzing, might need to bend a couple slightly, or maybe mount it ontop, or inbetween those 2 top mount points, and then also tweak the lower bracket if you need to angle it up a bit more to get clearance on the frame.

 

[454k30]

Are the mounting tabs in the right place on this one?

They were close enough that some light bending got them to where they needed to be. I also drilled out the mounting holes to accommodate the stock rubber mounting bushings. Also, the MAP port is not in the same location as the stock unit so you will need to route the wiring to that sensor a little differently. It's not really an issue, but just be aware so that you don't add a ton of pre-load to the wiring harness.

 

[shoebear]

Most/all all-aluminum aftermarket IC's are a bit thicker than stock, so the stock piping from the turbo outlet to the IC will need to be shortened. On my car, that has resulted in not being able to attach the pancake pipe to the frame of the car, because now the pancake mounting hole is aft of the stud about half an inch. So far, it seems to be doing OK with only the hose clamps holding it in place; and I'm sure I could find a way to mount it if I wanted to get creative in fabrication. But just FYI FWIW.