Tiguan S3 Intercooler Install Guide

[Ramee]

Well couldn't resist so took a quick trip into the office before lunch. This afternoon fitted up the new S3 intercooler....

Some minor challenges so I used the "phone a friend" lifeline. Turns out Ramee and I took slightly different approaches to removing the headlights and front bar plus hoses are different between 1st gen and second gen Tigs....

Managed to get 90% done in the afternoon and final bit of reassembly after tea. Off to do a test drive...


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Happy to hear everything went well congrats! May be you can do a detail DIY for rest of us Tig owners..

[tigger73]

Happy to hear everything went well congrats! May be you can do a detail DIY for rest of us Tig owners..

Unfortunately I didn't take many photos along the way as I was on a tight timeline (trying to get it finished in the afternoon).

However I did manage to take a photo comparing the two cores:




Top is the stock Tiguan intercooler (Part #: 3C0 145 805 R) and the bottom is the Audi S3 intercooler (Part #: 1K0 145 803 BE). This one has the plastic end tanks and is the newer style. Possibly the older S3 intercooler with metal end tanks is slightly better performance but this one was available at the right price.

DIY process is quite simple.

Remove everything in front of the intercooler/ A/C condenser:




Unbolt the condenser/intercooler/radiator, slide out the old intercooler and slide in the new one.

Put it all back together.

I managed to take off the front in two large pieces:

• the front spoiler/grille
• headlights/front bar

To do this I did have to unbolt the bonnet latch and remove the bonnet release cable so that I could remove the headlights/front bar as a complete unit.

Also the intercooler hoses/connectors were different between the "old" Tiguan intercooler and new S3 one. I had to do some minor surgery to the stock hoses to remove the metal connectors at the intercooler end so that they would slip over the connection (rather than fit inside the housing and be secured with clips).

It all ended up working out OK. I was a little concered that after I butchered the stock hoses that they wouldn't fit and I'd be left without any hoses and unable to fit my old intercooler back in. The S3 hoses are too short and are also the wrong shape on the turbo side to fit into the Tig, so you need to use your stock hoses.

[brad]

What is the thickness of the OEM intercooler?

S3 core with plastic tanks is 38.7mm - just trying to work out how much the Tig was hobbled ex-factory

You realise the plastic tank unit has these features over the S3 metal tank unit:

4 more bars spaced more closely together
* More equivalent frontal surface area, as well as internal cross sectional area - improved flow capacity

The plate design inside the bars are more closely packed
* Improved efficiency due to greater rate of heat transfer

Smoother flowing end tank ports
* Improved flow characteristics compared to the S3 fittings which have steps in diameter causing turbulence.

[tigger73]

What is the thickness of the OEM intercooler?

S3 core with plastic tanks is 38.7mm - just trying to work out how much the Tig was hobbled ex-factory

You realise the plastic tank unit has these features over the S3 metal tank unit:

Stock Tig intercooler is 32mm so S3 is 21% increase just in thickness. I'm not sure about how "dense" the S3 one is compared to stock Tig one but just with the thicker core it should be a reasonable improvement.

I figure if the S3 intercooler is good for power outputs around 200kW that should do me just fine

All mounting points are identical, so this is a bolt in bolt out job.




Here's the stock connection:




And carefully removing the aluminium end with a hacksaw and screwdriver making sure not to nick the hose.




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[tigger73]

The car does feel a bit more freed up with the new intercooler. I don't think it's the cooling effect as today is a mild day - 20 deg C.

I just think the stock intercooler was a bit restrictive and now with the S3 intercooler it feels like it allows better flow.


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[brad]

Stock Tig intercooler is 32mm so S3 is 21% increase just in thickness. I'm not sure about how "dense" the S3 one is compared to stock Tig one but just with the thicker core it should be a reasonable improvement.

I figure if the S3 intercooler is good for power outputs around 200kW that should do me just fine

All mounting points are identical, so this is a bolt in bolt out job.


And carefully removing the aluminium end with a hacksaw and screwdriver making sure not to nick the hose.




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Blimey! 32mm is the same as my 1.8tsi. I would have thought the Tiguan would have at least the Mk6 GTI 38mm IC.

I have the same S3 IC sitting at home waiting for me to replace the 32mm I have.

You should have removed the green O-ring & kept it as a spare as it is used in the pipework between the turbo & the IC

[tigger73]

Blimey! 32mm is the same as my 1.8tsi. I would have thought the Tiguan would have at least the Mk6 GTI 38mm IC.

I have the same S3 IC sitting at home waiting for me to replace the 32mm I have.

You should have removed the green O-ring & kept it as a spare as it is used in the pipework between the turbo & the IC

I know the 2012 update has a slightly different intercooler to the 2008-2011 Tigs. You'd have to get Ramee to measure his up if it hasn't already gone in the dumpster.

I'll go and fish the o-ring out and add it to my collection of "bits". Anyone need an intercooler o-ring send me a prepaid envelope and it's yours!!!!


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[Ramee]

I know the 2012 update has a slightly different intercooler to the 2008-2011 Tigs. You'd have to get Ramee to measure his up if it hasn't already gone in the dumpster.

I'll go and fish the o-ring out and add it to my collection of "bits". Anyone need an intercooler o-ring send me a prepaid envelope and it's yours!!!!


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Haha funny! I still have my stock intercooler and quick check showed it has a 37mm - 38mm width core. Its part number 3AA145805C
ebay link NEW GENUINE VW PASSAT TIGUAN 2.0T FSI CCZB TURBO INTERCOOLER 3AA 145 805 A | eBay

[tigger73]

Haha funny! I still have my stock intercooler and quick check showed it has a 37mm - 38mm width core. Its part number 3AA145805C
ebay link NEW GENUINE VW PASSAT TIGUAN 2.0T FSI CCZB TURBO INTERCOOLER 3AA 145 805 A | eBay

That is interesting. I'm wondering if it's because yours is a 155TSI and mine is a 125TSI that I got the smaller intercooler. I suspect this may be the case that the 147/155TSI get the upgraded intercooler to cope with the extra power. Just means that there's more to be gained for a 125/132TSI upgrading their intercooler than someone with a 147/155TSI.

I'll be interested to see what the dyno shows when I get back on there. If the intercooler was causing a pressure drop/turbo to work harder I should (hopefully) get better flows/more boost and theoretically more powa

[Wynnston]

Haha funny! I still have my stock intercooler and quick check showed it has a 37mm - 38mm width core. Its part number 3AA145805C
ebay link NEW GENUINE VW PASSAT TIGUAN 2.0T FSI CCZB TURBO INTERCOOLER 3AA 145 805 A | eBay

I think that was the same part number on my mates Golf R intercooler as well. He's upgraded to an APR and I was wondering if it would be an upgrade to snaffle his old one.