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Discussion Starter #1
I installed AWE Intercoolers as part of a recent K04 upgrade.
When running higher boost levels, the OE Intercoolers can cause ~2psi drop between Turbo's & Intake and become especially prone to heat soak in warm weather.
http://www.awe-tuning.com/page...olers
I must say that the AWE IC's are a Quality Product. The mounting instructions provide a general idea but by no means should be considered complete.
Some steps of the instructed mounting approach are just plain cheesy and could cause the IC's to develop a leak from contact vibration over time.
http://www.awe-tuning.com/medi...s.pdf



The AWE ICs are big and everything in the vicinity wants a rub. Inner bumper reinforcing structures were pressed against the AWE fiberglass shrouds causing the bumper to bulge out at the sides and not fit properly. The instructions do not mention trimming the reinforced corners of the inner bumper but it is required. A simple template would have saved the time of several bumper R&R test fits.

Instructions indicate to only cut driver side fender but I had to cut both fenders. Fabbed some stainless steel sheet metal brackets to solidify the Intercooler mountings. Without solid mounting brackets, my AWE ICs were floppy at best and I was concerned road vibration was going to damage them.
Driver side bracket was a piece of bent up work. Picked up the two IC shroud screws, the upper Fender to Lock Carrier bolt, the Horn bolt and the ATF Cooler mount tucked in behind the horn.

The driver side OE Intercooler had a bracket for ATF Cooler mount which is not included with AWE ICs. The driver side 1 pc stainless bracket reaches around back to pickup the lower ATF cooler mount.

Passenger side bracket. It's solid but I'll likely re-do this one to pickup the upper Fender to Lock Carrier bolt as I did for the driver side.

Being a Canadian B5 S4, there are no fog lights in lower grills to restrict and pre-heat inbound air. Since there will never be fogs on this car, I removed excess fog mount bumper material to increase IC airflow.
I left the vertical fog light supports in the grill openings for now as they seem to contribute to holding the vertical shape of the grill opening. I'm considering removing them later.
Before

After

AWE could have designed the shrouds a little better. They are certainly quality pieces but there is no need to wrap shroud around Lock Carrier and reduce the exposed IC surface area. Also, ideally the smooth side should be on the inside and not the outside of the shrouds.
Some shroud triming was required to clear the headlight washer cylinders. Caution as the cylinders could be damaged if bumper is forced on without triple checking clearances.
I am considering removing some of the shroud fiberglass around the Lock Carrier edges to maximize IC surface exposure.

Mmmm... a free Sucker... it was good!
I did not use the 2 cent piece of anti-vibration mounting foam from Instructions - Step 14.
I installed a few pieces of sheet rubber where IC's contact frame rails and custom brackets.

Can usually tell how much fun it was by the leftover bits.
Note the cut-off bolt and screw ends. If not careful, mistakenly installing all the OE bumper shock bolts will puncture the IC's!!! The instructions say to push the IC to the outside so that the upper outer bumper shock screws can bottom out - this is a BAD idea. Road vibrations will eventually blow a hole in the aluminum IC because they would be under tension and rubbing constantly on the protruding bolt tips. I chose to cut the excess bolt ends off the outboard OE Bolts. One must now be aware that the two outboard bolts are intentionally shorter than the others during future front end work.
The included shroud mounting screws were too long and were too close to contacting the IC face so I cut them to proper length as well.

The install is complete for now http://****************.com/smile/emthup.gif

I'm going back in one more time over the holidays to replace the worn plastic triangle bumper clips, re-do the passenger ss bracket and remove some of the AWE shroud fiberglass from the edges of the Lock Carrier.
Also going to thread half the mounting post to pull back and lock the bottom of driver IC.




Modified by GLS-S4 at 4:04 PM 12/10/2007
 

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Re: AWE Intercooler Install (GLS-S4)

Great write up.. thanks a lot man!! This should help me come spring when I put mine in... definitely more work then i thought it would be, but you definitely did it right with those custom brackets.

http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif
 

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Re: AWE Intercooler Install (dubsix)

Hey, there are a select few of us in the States with no fogs as well.

Though I didnt think to remove all the mounting, I need to do that, was it all plastic and simple cutting required?
 

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Re: AWE Intercooler Install (GLS-S4)

Hey GLS
Good write-up! It was suggested to me to get these next on the A6. Good to know that the install might not be as quick and easy as it looks.
[email protected] I need to get me one of those jacks!
That must make workign on the car a pleasure. ... not fight with a small 2ton jack and stands...
Cheers
Massboykie
 

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Discussion Starter #6
Re: AWE Intercooler Install (PhunkFX)

Thanks for the feedback guys http://****************.com/smile/emthup.gif
I would strongly suggest upgraded Intercoolers for ANY chipped 2.7T, especially in warmer climates. OE Intercoolers are designed for efficiency at ~9psi boost. Depending on chip, boost levels of 15 to 20+psi force the stock ICs to become an appreciable pressure restriction and increases heat accumulation... a double whammy! Chipped K03's very hi shaft speeds will be reduced to produce same ECU Requested Boost levels by removing ~2+lbs OE IC pressure drop as well as reduce heat soaking IAT's.
And K04's will just love 'em


Quote, originally posted by PhunkFX »
Hey, there are a select few of us in the States with no fogs as well.

Max IC airflow and lower IAT's by removing OE US Fogs... Props http://****************.com/smile/emthup.gif
Quote, originally posted by PhunkFX »
Though I didnt think to remove all the mounting, I need to do that, was it all plastic and simple cutting required?

Yes, plastic bumper skin and simple cutting. I did the varied bumper surgeries with bumper off car, but the fog mounts could definitely be shaved with bumper on car. I used a fresh Exacto knife, hacksaw blade and a file to cleanup edges.

Quote, originally posted by Massboykie »
It was suggested to me to get these next on the A6. Good to know that the install might not be as quick and easy as it looks.

AWE Instructions say 2.5 hours install time... maybe so if you have previous experience pulling front bumper, don't mind bumper not fitting properly and don't mind waiting for a floppy IC boost leak.
I spent 1 full day fitting AWE ICs in a way that I felt matched the investment and overall high product quality http://****************.com/smile/emthup.gif



Modified by GLS-S4 at 3:46 PM 11/12/2008
 

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Re: AWE Intercooler Install (GLS-S4)

http://****************.com/smile/emthup.gif
Thanks for the straight poop on the install.
 

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Re: AWE Intercooler Install (GLS-S4)

Quote, originally posted by GLS-S4 »
AWE Intercooler Christmas Sale started today for $200 off retail http://****************.com/smile/emthup.gif

Thats a great sale. I got mine during last year's Christmas sale! Thanks AWE.
 

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Re: AWE Intercooler Install (GLS-S4)

Great write up i was thinking about this mod down the road.. Cant install much with one hand.. Rockclimbing > me..
My car didnt come with fogs the PO must have had the same idea as you..
Where can you get grill inserts to cover up the cut outs for the fog lights? ECS?
Cheers
 

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Re: AWE Intercooler Install (Dowskeet)

Quote, originally posted by Dowskeet »
Where can you get grill inserts to cover up the cut outs for the fog lights? ECS?
Cheers


Canada http://****************.com/smile/emthup.gif
 

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Discussion Starter #13
Re: AWE Intercooler Install (Dowskeet)


Or you could RS4 the hood grill and mesh mod all lower grills. I'm considering doing that one, maybe next summer http://****************.com/smile/emthup.gif
 

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Re: AWE Intercooler Install (PhunkFX)

Quote, originally posted by PhunkFX »


Canada http://****************.com/smile/emthup.gif

Damn you guys..

 
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