Stock intercooler replacement S6 2.2t

[Wrath]

Hi

Anyone that has replaced the stock intercooler? Was about to wait until I have done the new motor and go with a bigger aftermarket front mounted. But the 21 year old intercooler cracked today. (plastic version) So i ordered a better used one from the S4 (full alu version). Just wondering if anyone has changed their some time? Can you do it from under the car without pulling the front? Mine is attached in a way that I rather skip that.

[UrS4boy]

C4 UrS SMIC and bumper info

Hi Anyone that has replaced the stock intercooler? ... the 21 year old intercooler cracked today. (plastic version) So i ordered a better used one from the S4 (full alu version).

Very common issue with the UrS6. That and the plastic cross-over tube splitting. If you are not going FMIC, best to replace both the SMIC with an UrS4 unit and the cross-over tube with the metal UrS4 tube.

You will need to remove the front bumper. (Relatively easy). Re-installing the bumper is best done with a helper because you need to get the bumper side wings snapped into the mounting brackets on the fender.\

C4 Bumper 101:

http://forums.quattroworld.com/s4s6/msgs/116410.phtml

Some NAmerican C4 UrS 100/A6 front bumper removal and replacement hints:

http://forums.quattroworld.com/s4s6/msgs/239435.phtml

[Wrath]

Super, Thanks for that...

[macspring]

Hi Wrath,

I didn't want to cut up / trim my euro bumper, and was thinking that if one could find a thin suitable sized intercooler to augment the existing oem intercooler, having two would be enough of an improvement.

Haven't done much more than thinking about it at present.

Just a thought. The intercooler I have in mind would have to be custom made rather than an e-bay special due to the 'odd' size required.

Interested to see how you get on with this 'problem'.

[UrS4boy]

I didn't want to cut up / trim my euro bumper, and was thinking that if one could find a thin suitable sized intercooler to augment the existing oem intercooler, having two would be enough of an improvement. Haven't done much more than thinking about it at present.

I guess you missed this (below). And with a small FMIC the pressure loss rate per cm of travel will be even higher than what I suggest in a general sense below:

..I hope you remember the law of diminishing returns. The SMIC in series with the FMIC will add very little temperature drop but a significant pressure drop (bad). You would probably be better off just going for a water/methanol injection system ahead of the stock SMIC.

[popdemonic]

What if i add another SMIC instead of the stock oil cooler location?just exactly like on 2.7TT?Anyone BTDT?
I don't want to cut the euro bumper and personally i'd like to keep it like OE-like sleeper look.

[Wrath]

Its cool wheater here in Sweden so If you dont aiming for over 400 HP oem cooler is fine
Will probably cut a little to The bumper in The future but for now a better stock cooler is enough

[popdemonic]

poor in Thailand Goeran.few days ago,07.00 in the morning,i WOT on my car and intake temp ramped up to 94C.crazy heat soaked here.

[Wrath]

94 !!! I have seen up to 45 degree celcius IAT when ive parked it on a warm day, normal IAT when I drive is 25-30

[UrS4boy]

What if i add another SMIC instead of the stock oil cooler location?just exactly like on 2.7TT?Anyone BTDT?

Pop: Agree that the 2.7tt has two SMIC but each effectively one serves one 3 three cylinder engine, they aren't in series the way you are proposing. For an AAN, with two SMICs in series, the second intercooler in the flow path will contribute as much additional pressure drop as just one intercooler but only a fraction of the cooling power of the first one.

2.7TT:

[macspring]

Hi Dave, I did miss that post.

I was basing my suggestion of DJ Jones's white ur quattro, but I accept what you're saying.

Thanks as ever for your input to these threads.

You're on point.

[macspring]

.............. and personally i'd like to keep it like OE-like sleeper look.

Absolutely, cars look cat when you see a big silver intercooler and pipes poking through a mutilated front bumper.

imho.

[UrS4boy]

Absolutely, cars look cat when you see a big silver intercooler and pipes poking through a mutilated front bumper. imho.

Admittedly it is a NAmerican front bumper with more room but can you see the 3" thick Apikol FMIC behind it? No. Look stock? Yup. The back of the bumper plastic has been trimmed but the large metal "rebar" (massive member) is untouched. It is possible with a Euro bumper and a 2.5" core with some judicious trimming.

[popdemonic]

Thanks Dave! the main reason i still "untouch" the FMIC mods since it requires a lot of trimming behind the bumper.
some needs to trim the both lower grills,some needs to cut the lower valance which that is the same piece with the bumper(the Euro A6 C4 bumper has separate piece with the bumper).

@Goeran,The intake temp at idle when it's parking standstill is 63-73 Deg C.No surprised when i see 90+ Deg C under WOT lol.

[prj]

The SMIC does not flow enough even for a mild upgrade beyond stock turbo.
It also does not cool properly. Fitting two of those is just retarded.

It is possible to fit a custom FMIC behind the front bumper and retain the stock look. Yes, the front bumper will need to be "modified" in some places.

Pop: Agree that the 2.7tt has two SMIC but each effectively one serves one 3 three cylinder engine, they aren't in series the way you are proposing.

Incorrect, each serves one turbocharger. They are in parallel because the car only has one throttle body.

Of course comparing this to the 2.7TT is silly in the first place. If you want to compare it to anything it would be the 3.0 TDI which has a dual SMIC setup on the C6/4F chassis.

Regardless, there is a proven and working solution. These threads will keep popping up every now and then though - same as threads about water to air coolers (utterly pointless on a street driven car with the engine in the front) and so on.