Tiguan S3 Intercooler Install Guide

[Ramee]

Today I was able to install S3 intercooler for Tig. I did it solo with in about 6 hours time and without too much struggling. Tig has bit more ground clearance than GTI s so I did not have to jack it up during the swap. I got two hoses with the S3 intercooler but one of them (pre intercooler/ turbo side) one is too short for Tig. So I used stock hose but had to cut about half an inch to clear the swelled area of the hose and to get the perfect length. For the other side of the intercooler, I could use the S3 hose easily. I used APR and other internet resources as a reference and even though they are for GTIs, still closely relevant for Tigs.

Some pictures of the install.

Front bumper removed.


Water is leaking because I forgot clamp the headlight washer line!


Bumper bar, headlights, and intercooler supporting bracket removed.


No need to remove the hood unlocking wire in Tigs. Just leave the supporting bracket away with wire attached.


Intercooler is in between two radiators (AC and Engine coolant). Just unbolted both of them from the intercooler.


S3 vs stock intercooler. Not much difference in size S3 may be 4mm thicker than stock and has aluminium end tanks.


S3 is about to go in. Stock one is going to garbage


S3 intercooler in the car!



Did a test drive, car feels bit livelier. But today is not a very hot day so benefits will be more clear in a 30+ degree day

[tigger73]

Today I was able to install S3 intercooler for Tig. I did it solo with in about 6 hours time and without too much struggling. Tig has bit more ground clearance than GTI s so I did not have to jack it up during the swap. I got two hoses with the S3 intercooler but one of them (pre intercooler/ turbo side) one is too short for Tig. So I used stock hose but had to cut about half an inch to clear the swelled area of the hose and to get the perfect length. For the other side of the intercooler, I could use the S3 hose easily. I used APR and other internet resources as a reference and even though they are for GTIs, still closely relevant for Tigs.

Nice job. Are both the stock hoses a little too long? Just in case I don't get hoses with the intercooler...

So did you get your sway bar fitted too? or has that been pushed out to next weekend?

S3 vs stock intercooler. Not much difference in size S3 may be 4mm thicker than stock and has aluminium end tanks.

S3 is about to go in. Stock one is going to garbage

I'm guessing this will be a one-way install for me too. Given the time taken to put it in, it doesn't seem worth it to pull it out afterwards. Though I'll probably keep the stock intercooler anyway (and worry abouth te cut hoses later).

Did a test drive, car feels bit livelier. But today is not a very hot day so benefits will be more clear in a 30+ degree day

I'm not sure it's going to be noticeable. Maybe just a placebo effect

[Ramee]

Nice job. Are both the stock hoses a little too long? Just in case I don't get hoses with the intercooler...

So did you get your sway bar fitted too? or has that been pushed out to next weekend?

Yes both stock ones are little too long.. Not much, may be extra half an inch long. Problem with them is stock intercooler inlet and exits are bit larger than S3 intercoioler ends. So these stock pipes go loosely over the S3 ends. Better to cut stock piping ends bit to get more through fit and avoid the swelled area of stock hoses.

I could not install my sway bay yet because I was very tired after end of this exercise. Good thing is I have something to do again to the car next weekend too

I'm not sure it's going to be noticeable. Maybe just a placebo effect

He he.. May be, but to motivate you I would say it gives extra 10 hp in hot days

[Ramee]

Some data logs of intake air temperatures with stock and S3 intercoolers installed. They logged in nearly similar times of different days with ambient temperatures nearly same on same path from my work to home. Logs show a very clear decrease in intake temps with S3 intercooler even though it is not an ideal intercooler, still heat soak little bit at traffic lights.

[tigger73]

Some data logs of intake air temperatures with stock and S3 intercoolers installed. They logged in nearly similar times of different days with ambient temperatures nearly same on same path from my work to home. Logs show a very clear decrease in intake temps with S3 intercooler even though it is not an ideal intercooler, still heat soak little bit at traffic lights.

Nice work Ramee. Always good to have the hard facts to support spending the time and $.


Sent from my iPhone using Tapatalk

[tigger73]

A box arrived the other day while I was away

[team_v]

Keen to see what was in the box!

[tigger73]

Keen to see what was in the box!

So am I! It's currently sitting out in the warehouse at work... May have to visit the office on the weekend to collect it.


Sent from my iPhone using Tapatalk

[Ramee]

So am I! It's currently sitting out in the warehouse at work... May have to visit the office on the weekend to collect it.


Sent from my iPhone using Tapatalk

I think I know what it is Haldex ? or may be intercooler !

[tigger73]

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...


Sent from my iPhone using Tapatalk