AchTuning Intercooler install DIY

[EvilGLi]

Let me first say, that there were no directions with the intercoolers. Tony(car owner/friend) and myself were bummed on this, as they had ZERO instructions. The quality is quite good on the cores, the end-tanks are close to stock, of course getting a bit wider due to the size of these intercoolers, which they are fairly large.

You will have to grab a few things to do this, here is what is neeed that most won't have:

rivet gun
cutoff wheel/dremmel
patience( i lack it sometimes)
hose clamp pliers
squeeze clamp pliers
coolant bucket
bottle of G12 and some water
drill and bits
patient friend


The car was already on it's way in the modding world, previously we had done boost hoses and exhaust. If you have done boost hoses and you have these....this would most definetely be the best time to do both. It's much easier this way.






First thing, remove wheels and remove the screws holding the fender liner in, fully removing the fender liner makes the install ALOT easier.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-53.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-52.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-50.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-49.jpg

Next, remove your belly pan, I am truly hoping you've done this before, because i didn't take pics

then remove grille inserts and remove the two bumper bolts,8mm allen, and some torx screws and the foglights covers(phillips screws)then remove the foglights as well. there is also 3 torx on the top of the bumper(front grille area)
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-51.jpg

Once you remove the bolts and such, go back into the fender well, look at those frames for the intercoolers..kiss them good bye. then note the three 10mm nuts, remove these for they hold the bumper on as well. if you can unplug the fogs and head lights now.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-47.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-46.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-45.jpg


Now look under the car and take note of the dual secondary radiators.these will be fun :] we took off the framesbehind the coolers now, here is a pic minus the frames, you can see the secondary's well here
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-38.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-45.jpg

Now we can take the bumper off, remember that when doin this you will need to disconnect the horns and on the drivers side, the headlight washer line. if you have two people(recommended) this will be much easier.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-43.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-42.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-44.jpg

next we are going to remove the headlights..this makes things ALOT easier. we didn't get good pics, but there is a reallllyyy annoying torx bolt you will deal with..because i am mean spirited...you'll find out
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-39.jpg


remove the boost hoses under the car, and the allen bolts on the lower inside.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-56.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-54.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-37.jpg

also remove the outer front fender bolt and the lower fender support torx bolt(behind intercooler) your going to need the fender flexible.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-36.jpg

now remove the front air shrouds, cos these are gonna go to the trash(kit comes with carbon fiber replacements)

http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-40.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-41.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-39.jpg

next you will clamp off the coolant lines(upper and lower) and use the squeeze clamp pliers to loosen and move the clamps back. also remove the bolt holding the lower hose to the intercooler.prepare a bucket,etc to catch the coolant in the secondary's.remove the hoses and now we are ready to remove the intercoolers.

upper hose
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-31.jpg
lower hose
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-30.jpg

removal is good exercise, your gonna need to muscle it out. once out the fun begins.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-29.jpg

holding the secondary's in are rivets and some shrouds. drill out the rivets and remove the secondary's.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-33.jpg
sorry about the lack of pictures here, we hit stride and it was midday so it was effin HAWT.

anyway, once you remove the secondary's, get all the robber grommets and put them on the new shrouds for the secondary's
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-32.jpg

here is a comparison of the coolers
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-20.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-19.jpg


auyrte, now let's get those secondary's secured. place the secondary's in the shrods and then on the intercoolers, line up the side holes and have your pal hold em there. grab your rivet gun and use the rivets supplied to rivet the secondar's to the coolers.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-28.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-26.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-27.jpg


now the fun really begins, place the intercooler back in it's lovely little space, having the upper boost hose removed is a good thing. once you have the intercooler in, secure the lower hose(just put it on) and reinstall the secondary's hoses and clamps. this will hold the cooler in place so you can reinstall the upper and lower boost hoses. then the lower allen bolt for the cooler, also put the fender bolts back in as well(front and rear lower).

http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-22.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-21.jpg

btw, you will need to remove a bolt piece from the lower secondary hose, careful..don't cut your coolant pipe and make sure you remove the sharp edges as well.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-25.jpg


we did the passenger side first cos it as easiest. and it will help you learn the layout fo the cooler and secondary.

for the drivers side you have some extra headaches

for instance, the power steering resivoir and washer fluid resivoir.this will be a bit tougher for headlight removal as well.

remove the intake duct, then remove the cover around the power steering resivoir and pull th econnector sout fo the holder, then remove the connector holder, it's a PITA, second set of hands pays off here.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-18.jpg

now you can remove your upper boost hose and such.
some pics of drivers side.

http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-17.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-11.jpg

repeat steps for removal and installation


now that the lovelies are in and everything is secured, we can get to the fun stuff. we left the headlights out till the end btw.

now we can install the carbon fiber shrouds...these are very very rough molds, so you have to trim them in order to reinstall the front bumper. i was fairly upset with this..considering the price, this should've been taken care of by the manafacturer. once their on, we can get to trimming.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-16.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-23.jpg

on the both sides, they need to be trimmed in the same spots essentially.
upper inside
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-4.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-3.jpg
upper outside
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhitesan.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-5.jpg

and some shaving all around. then you can try to reinstall and check for any other hang ups.
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-10.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-8.jpg

[[once done with that we secured the lower secondary hoses to the new shrouds so they don't hang, we jus zip-tied them.]]


make sure to double check everything once again, boost hoses, coolant lines to secondary's,etc,etc,etc then reinstall the headlights.when reinstalling the bumper, some force may be needed, and make sure you get all your horns and lights reconnected and reinstall the fogs after the bumper is on, so you can insure a good bumper fit first.once again, a second person makes fitting and such easier so you can apply force to get a good tight fit.

http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-2.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-13.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-12.jpg

then after another good check over that you got the bumper bolts good and tight and all the little torx, you can reinstall the grill pieces( we used the stock pieces)
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-14.jpg


now jus good once over and you can crack your coolant bottle and massage some coolant lines ot helpw ith airpockets, then add some water and coolant, put cap back on and start here up. good to have a vagcom so you can watch some blocks and checkfor leaks of any kind(boost or coolant). a few good test drives and you'll notice a bit smoother boost ramp up, better cruising and standing temps(boost) and a bit of smoothness.

some extra pics.

http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-6.jpg
http://i4.photobucket.com/albums/y110/UNGLUCK/car%20i%20have%20built/tonysintercoolershanaumabaywhite-15.jpg
my car
http://i4.photobucket.com/albums/y110/UNGLUCK/mkI%20jetta/62509HDRshootatkalealoa191And10more.jpg

auryte guys!! i hope this helped, sorry it wasn't as detailed as we planned and sorry no suspension DIY yet, but that is coming!!!!!

we wanted it to be more detailed but time constraints, heat and well, jus being involve din what we were doing got the best of us,lol.

tony's car fukn gorgeous and SIK. and he's the man. love the guy. hopefully we'll be back soon with that KW V3 install.

maybe tony can slap a full list of mods on here for his car :]:rs6kiss::race::applause:

[DuckWingDuck]

thanks for the excellent writeup! Now, about those performance gains.... :D

[EvilGLi]

well at idle i saw a few degrees drop in intake temps already, after 20 minutes of idling and a few 2 and 3 minute stints of idling, they were good and heat soaked and you could still the they flow better and cool better. boost response was fuller and boost held better and filled faster.

i did some timing tweaks and so far, it seems great. tony has to really give that insight since he drives the car.

i do have to say, for the cost of the intercoolers, i was rather pissed they were so roughly done and had no instructions. but eh, that's what a good community following is for.

thanks a ton :]

[ben916]

Great write up!

And photos! This needs to be a STICKY for DIY

[Beastly]

Awesome write up - Thanks!

[Spidercat]

+1
Great write up, EvilGLi!
LOL "We wanted it to be more detailed, but..." Thanks for doing all that! I know my camera would've been packed away after only the first round of curses!
BTW, I had a '82 Jetta (but diesel). I got well over 50 mpg. I think I filled the tank 4/times year!

[DHall1]

I was going to say...

THIS THREAD IS WORTHLESS WITHOUT PICS.

But, clearly that is not the case.

Cheers+1

Sticky! And a good subject title to make searches easy.

Also of note....notice the leaking stock intercoolers. hmmmm

[DHall1]

GLi

How are you making "timing tweeks"?

What tuning program does this car have?

[EvilGLi]

this car is APR, but i have a dealer limited edition version of unisettings from unitronic..and since Frieling makes practically EVERYONES tuning software, i can access the eprom and ram tables and do broad tweaks.

my car is one of my first cars without standalone, so i have some experience in tuning. i noticed in some logs and measuring block watching previously, that he had alot fo timing jumps that could be smoothed over the whole rpm range.

i hope one day i can plu gin and we can get some solid logs, but it would have to be a weekday and midday, which is hard since tony(owner) is military and usually works during those times,lol. plus we're on an island and the highest speedlimit is fukn 55....total bummer.

thanks for the props guys, the suspension DIY will be much much more detailed.and once i get some more practice in on my new welder..i want to fab up some intake pipes, cos this car could use some more fresh air.

[ben916]

thanks for the props guys, the suspension DIY will be much much more detailed.and once i get some more practice in on my new welder..i want to fab up some intake pipes, cos this car could use some more fresh air.

Scrapping the DRC and going with what?

[EvilGLi]

KW variant 3

concerned on how to remove the DRC pump...as i am unclear as to how the process goes. don't want 65 bar of pressure in my hands suddenly...not a good scenario.

[hahnmgh63]

No problem on the DRC removal. I pulled it all including the cross connected hardlines to get rid of every piece. The accumulators/Central valves and the shocks have check valves so you will only get a little bit of the shock oil draining out of the lines, no explosions. After you pull all of the junk just silicone up the holes in the trunk where the thru bolts for the central valve brackers were and your done. Yes, the silicone weights a lot less than the steel brackets if anyone is wondering why I unbolted them.

[AudiRS4ever]

I went to their website and it only shows diverter valves for the RS6. Do you have to call them to get a price?

[s42ski]

Great write up and photo's. Your old intercoolers look like mine today - leaking a little at the bottom.....
I doubt this is a fixable item if brought to the attention of the dealer ???

[Lupo911]

hmm, you can Download the Instructions online

http://www.wagner-tuning.de/Montageanleitungen/Montageanleitung-Audi-RS6-und-US.pdf

there is also no cutting on the Shrouds needed

but very nice Write up... sorry for that trouble, maybe next Time just ask the Company who sold you that Intercoolers for Instructions...

[RS6-4dr911]

Also of note....notice the leaking stock intercoolers. hmmmm

Mine have the same stains, asked the dealer to check it out when I took it in for the DRC replacement. "Everything's fine". Me thinks not.

[AudiRS4ever]

Ok, now I am really confused. I just spoke with Achtuning and they do not sell the Wagner intercoolers that you installed. They are a little bit confused too after I told them that you purchased the intercoolers from them. :vhmmm: Could you confirm you did indeed buy the intercoolers from Auchtuning?
I was really excited when I heard you say it was Auchtuning, because they are one of the few companies I actually like. They still understand customer service.

[V8weight]

As far as I'm aware, they are only available state side through 034 motorsports. http://www.034motorsport.com/product_info.php?cPath=21_92&products_id=19214

[AudiRS4ever]

As far as I'm aware, they are only available state side through 034 motorsports. http://www.034motorsport.com/product_info.php?cPath=21_92&products_id=19214

Thanks Pat. I've decided to keep the RS6 through the winter and am looking for a project. I was thinking KW's, but got curious about the intercoolers. For the price, I think I'll go with the KW's. I appreciate the link though. :race:

[V8weight]

Thanks Pat. I've decided to keep the RS6 through the winter and am looking for a project. I was thinking KW's, but got curious about the intercoolers. For the price, I think I'll go with the KW's. I appreciate the link though. :race:
I know that working DRC is great, but you won't be disappointed with the KW's. The handling is phenomenal and it's nice to be able to adjust your ride height. I would recommend the H-Sport sway bars if you don't have them already.

[mimors6]

JUST GREAT!! Thanks a lot man. Now it is no problem and no stress to do the changes!!

hmm..now just to find somebody who made the Kw3 change and the instructions

[AudiRS4ever]

I know that working DRC is great, but you won't be disappointed with the KW's. The handling is phenomenal and it's nice to be able to adjust your ride height. I would recommend the H-Sport sway bars if you don't have them already.

You're right about a working DRC, but I'm not happy with the Allroad look. I do already have the H-Sports and love them. I love the way your car looks.

[EvilGLi]

actually i did contact the maker and 034 about the intercoolers and they had nothing to say and never got back to me.

and they do need trimming, if you compare them to the stock shrouds they are much larger and the stock shrouds have grooves and such in them in the spots we cut.



eitherway, i still feel they are over priced. i put my air to water system together for 300 bucks, and it's 700hp capable and nets lower temps in standing traffic cruisin and full throttle beating. i wanna fab a setup for air to water for the RS..it'd be sick.

[Lupo911]

very Interesting, who is the Maker of these Kit and how did you contact them?



actually i did contact the maker and 034 about the intercoolers and they had nothing to say and never got back to me.

and they do need trimming, if you compare them to the stock shrouds they are much larger and the stock shrouds have grooves and such in them in the spots we cut.



eitherway, i still feel they are over priced. i put my air to water system together for 300 bucks, and it's 700hp capable and nets lower temps in standing traffic cruisin and full throttle beating. i wanna fab a setup for air to water for the RS..it'd be sick.

[Daniel]

hi guys...

sorry, that I must say my words on this thread...but I have installed the intercoolers and there were no problems...plug and PLAY ! :rs6kiss:

also you can download the installation guide on the manufacturers webpage...I think the problem is made by the intermediate dealer, who let you stay in the mist !

I am not the only one with these coolers, most of the german guys already installed these and all seem to be happy with them :revs:

always remind, you get what you pay for...

[EvilGLi]

see i keep hearing that..but the shrouds were very brittle, badly cleaned up and didn't fit well. we tried moving things and such but they just wouldn't cooperate then compared to stock, they are def better in how they route the air..but they fit like a glove now.

either way. spool is healthier, more robust and holds much better through the band. def better temps all around. they look great in the car and do their job very well.

these we're bought through a group buy on audizine i believe.