Fitting RS2 Intercooler

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  • stevieyid
    S2Forum Fiend
    • Apr 2005
    • 2251
    • Country: England

    #16
    Can yo fit it without having to jack the front of the car up? I dont have any stands at the moment.
    3'' Longlife Exhaust, Koni Adjustables, H&R Springs, Full RS2 Setup with Mr Nugents RS2 Chips (just need the RS2 Airbox)

    Comment

    • Jamo
      Retired OG Mod
      • Mar 2004
      • 21750
      • Country: United Kingdom

      #17
      Originally posted by stevieyid
      Can yo fit it without having to jack the front of the car up? I dont have any stands at the moment.
      Jack the car up?!

      No it's not required.

      Comment

      • Ross
        S2Forum Possessed
        • Aug 2005
        • 3399
        • Country: England

        #18
        Yes it's a really easy job, once you've got the front bumper off - that is the hardest part!

        The X-member is literally 3 bolts on each side, and pull it off with the IC connected. After you've taken the hoses off of course!

        As mentioned stock pipes should fit (did for me) if it's an ABY, I fitted one to my 3B XM once using cable ties while a custom mount was cut, and cut back the boost pipe. Really was easy and I was mechanically inept at the time.
        AUDI - saving Dad's from minivans since 1994

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        • Jamo
          Retired OG Mod
          • Mar 2004
          • 21750
          • Country: United Kingdom

          #19
          Originally posted by Ross
          I was mechanically inept at the time.
          @ the time?

          Comment

          • Ross
            S2Forum Possessed
            • Aug 2005
            • 3399
            • Country: England

            #20
            Originally posted by Jamo
            @ the time?
            Says him with the engine that STILL isn't running...

            *all fingers crossed for tomorrow's driveway session so I don't have to eat my words*
            AUDI - saving Dad's from minivans since 1994

            Comment

            • Jamo
              Retired OG Mod
              • Mar 2004
              • 21750
              • Country: United Kingdom

              #21
              Originally posted by Ross
              Says him with the engine that STILL isn't running...

              *all fingers crossed for tomorrow's driveway session so I don't have to eat my words*
              Do you really want to go there?

              Anyhow, it's bumper and fit and forget for the rs2 affair, just notch the cooler

              Comment

              • stevieyid
                S2Forum Fiend
                • Apr 2005
                • 2251
                • Country: England

                #22
                Is the oil duct needed or can i just remove it? I have the bumper off and cant disconnect the hose because the oil duct is in the way. Having problems getting the oil duct off because the screws have rusted!
                3'' Longlife Exhaust, Koni Adjustables, H&R Springs, Full RS2 Setup with Mr Nugents RS2 Chips (just need the RS2 Airbox)

                Comment

                • Jamo
                  Retired OG Mod
                  • Mar 2004
                  • 21750
                  • Country: United Kingdom

                  #23
                  Why are you removing it??????????????????????????????

                  Comment

                  • stevieyid
                    S2Forum Fiend
                    • Apr 2005
                    • 2251
                    • Country: England

                    #24
                    The hose clip is pointed towards it so i cant get to the clip to get the hose off. Can i just cut the side of the duct off with a hacksaw?
                    3'' Longlife Exhaust, Koni Adjustables, H&R Springs, Full RS2 Setup with Mr Nugents RS2 Chips (just need the RS2 Airbox)

                    Comment

                    • stevieyid
                      S2Forum Fiend
                      • Apr 2005
                      • 2251
                      • Country: England

                      #25
                      Now just found a bolt attaching the crossmember to the aux rad that i cannot get it off Any ideas on how i can get it off?
                      3'' Longlife Exhaust, Koni Adjustables, H&R Springs, Full RS2 Setup with Mr Nugents RS2 Chips (just need the RS2 Airbox)

                      Comment

                      • Ross
                        S2Forum Possessed
                        • Aug 2005
                        • 3399
                        • Country: England

                        #26
                        Can you get a 6 or 7mm socket on a rachet in there? That's how I get to those awkward clips...

                        I don't run with an oil cooler duct and never had problems, but if I had one I woud fit it as it makes sense. So I'd say try and get it off first, if not, you may get some room by taking off the X-member and IC and moving it slightly to the right. The hoses have a bit of flexibility.

                        As for the Aux Rad, I don't have either so sorry can't help there. If I remember it has 2 bolts on the bottom that should be fairly easy to remove? Can you take a pic?
                        AUDI - saving Dad's from minivans since 1994

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                        • stevieyid
                          S2Forum Fiend
                          • Apr 2005
                          • 2251
                          • Country: England

                          #27
                          Thanks for your help Ross. Just got it all off but now i cant get the clipe off the hose as its to old and where you put the screw driver cant take the force when yo utry and turn and just breaks.
                          3'' Longlife Exhaust, Koni Adjustables, H&R Springs, Full RS2 Setup with Mr Nugents RS2 Chips (just need the RS2 Airbox)

                          Comment

                          • Ross
                            S2Forum Possessed
                            • Aug 2005
                            • 3399
                            • Country: England

                            #28
                            Never an easy job eh... I had a similar problem, I got heavy-handed and cut it off. Of course I mangled the hose but I was cutting it back anyway as it was a 3B. If there's enough hose, you may be able to cut it just behind the jubilee clip and then fit a new clip aftward, you'll have to judge that one though - could be costly if not!

                            First off if the screwdriver won't fit, try and use a socket before you mangle it beyond that even! Usually they're 6/7/8mm but if it's rusted it may be too late for that anyway...

                            Any motor shop (Halfords etc) will have a selection of jubilee clips, you can get some heavy duty ones online as well. For a very temporary solution a couple of cable ties and gentle driving will get you there if it's your only set of wheels...
                            AUDI - saving Dad's from minivans since 1994

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                            • stevieyid
                              S2Forum Fiend
                              • Apr 2005
                              • 2251
                              • Country: England

                              #29
                              In the end i broke the clipe of and fitted anew one. I have it connected up now. Just a quick question should there be a hose where the intercooler goes into the cross member (on top right of the intercooler as u look at it?) The aby intercooler didnt have a hose but i thought it was supposed to.
                              3'' Longlife Exhaust, Koni Adjustables, H&R Springs, Full RS2 Setup with Mr Nugents RS2 Chips (just need the RS2 Airbox)

                              Comment

                              • Ross
                                S2Forum Possessed
                                • Aug 2005
                                • 3399
                                • Country: England

                                #30
                                Yes and No

                                It was never intended to, if you look there is an O-ring inside the intercooler to create a seal where the cross-member metal pipe slides in. However it's rubbish and is the cause of many a boost leak! One option is to get a fatter O-ring to create a tighter seal.

                                The other option, is to get a piece of hose and stretch it over - or you can get a silicone 60-70mm reducer pipe and cut it short enough to fit - and put jubilee clips on it. That's what myself and many others have done!

                                Search "Mark H mod" for more info.

                                Cheers
                                Ross
                                AUDI - saving Dad's from minivans since 1994

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