MK6R/Later S3 Intercooler - core dimensions

[brian_badonde]

As per my other thread, I've decided to upgrade my IC whilst changing out a duff radiator. I got hold of a Nissens IC which I believed to be the Mk6R/Mk6 GTI version, equivalent to the following OEM part numbers:

3AA145805C
1K0145803BP
1K0145803AK
1K0145803BE
3AA145805A

Here's the thing. It showed up and quality-wise it looks great, but the core looked surprisingly skinny. I checked the measurements on Nissen's catalogue:

625 x 405 x 32mm
=8.1 Litres

Comparing this with the MK5 IC from Nissens catalogue:

616 x 407 x 32mm
=8.023 Litres

This works out at a 1% difference in volume rather than the 25% I've seen quoted elsewhere. Am I missing something here? I thought the MK6R IC was supposed to have a 38mm width core?

For reference here's the Nissen numbers and link to catalogue if anyone's curious:

MK5 GTI - 96715
MK6 R/GTI - 96542
https://catalogue.nissens.com/Product

[brian_badonde]

I've checked Valeo's catalogue too, same story.

[LC5F]

Yes - I tied myself in knots over intercooler upgrade, I saw some with cores that looked a lot skinnier than OEM ones - IIRC there is a (pretty lengthy) thread on hear that looks into at all the different types.
I ended up getting a chinesium mishimoto clone that took month to arrive - hoping to get this on the Golf soon.

[brian_badonde]

Must have missed that one. Saw lots of bickering about plastic Vs aluminium end tanks but nothing relating to skinny cores.

Would rather send it back than do the job twice but it seems to be the right one. I wonder if core volume is a red herring as it's the total surface area that affects cooling capacity.

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[LC5F]

That sounds about right -
S3 good, but heat soak can be an issue
Mk6 good due to plastic, creating less heat soak...
But if your out on track you should have good airflow so I would say its horses for courses

Forgot to ask  - Where abouts are you in the central belt of our little big country? - i'm in reekie

[brian_badonde]

I'm just outside of Perth so not a million miles away!

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[Jb55]

Im pretty sure the nissans one people use has the code 96420

[bobby_fodge]

When I put my existing mk5 one against the new S3 one there was only a small difference in core width but so little so I did doubt I'd bought the wrong one and went back and checked the part number. I had bought the S3 one.

Maybe the S3 core differs internally?

[brian_badonde]

Im pretty sure the nissans one people use has the code 96420

Yeah that's the old S3 IC.

When I put my existing mk5 one against the new S3 one there was only a small difference in core width but so little so I did doubt I'd bought the wrong one and went back and checked the part number. I had bought the S3 one.

Maybe the S3 core differs internally?

That's encouraging. Think you're right about it being different internally, just found this from ECS tuning posted on golfmkv.com:

As requested - Here are is some of the information we found when researching the Golf R intercooler:


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.

So it looks like external core volume is indeed a red herring and the newer IC makes up for it with the above. Either way it looks like I have the right part, so mystery solved 

[pudding]

Just to confirm, I bought 1K0145803BP (Golf 6 R) back in 2016 from my dealer.  I measured the core depth at around 40mm, or could be 38mm as Brian mentioned in the OP, vs 32mm for the GTI one that I took off the car.

Obviously the updated intercooler core can't be too much thicker than GTI otherwise the radiator stack won't sandwich together nicely.  I do remember the 6R cooler almost touching the radiator after fitment, whereas the GTI cooler had a much bigger air gap.

Anyway, I'm sure the newer stuff is fine even if dimensionally identical. Technology is constantly moving on.

FWIW, the old all alloy S3 one was a heavy sod.  The later plastic ended ones are very light for their size.

[GVK]

Great thresad, thanks for confirming about the 6R cooler Kev.

[pudding]

It's a great upgrade    I paid £276 for it 5 years ago, which at the time was dirt cheap for an OEM intercooler, but like everything else now, prices are soaring!

I think for most people, the main benefit of the 6R cooler is ditching 2 of the annoying leak prone bayonet connections 

I've data logged some impressive intake temps with this cooler.  The GTI one heat soaks pretty quickly with sustained full throttle pulls, but the 6R one maintains good temperatures 

45 degrees C is the critical temp zone.  After that, the ECU starts yanking the timing back.  I've never got even close to 45 with the 6R 

[GVK]

Octane booster required then lol!!! I've been running octane booster in mine recently, its absolutely flying.

[GVK]

It's a great upgrade    I paid £276 for it 5 years ago, which at the time was dirt cheap for an OEM intercooler, but like everything else now, prices are soaring!

I think for most people, the main benefit of the 6R cooler is ditching 2 of the annoying leak prone bayonet connections 

I've data logged some impressive intake temps with this cooler.  The GTI one heat soaks pretty quickly with sustained full throttle pulls, but the 6R one maintains good temperatures 

45 degrees C is the critical temp zone.  After that, the ECU starts yanking the timing back.  I've never got even close to 45 with the 6R 

What group is the IATs I need to check mine.?

[pudding]

What octane booster are you using mate?  I used to use Millers CVL back in the day, which turned the piston crowns orange 

TBH I find V Power is OK.  I'm not getting any timing pull with the Revo 1 map 

I can't remember mate.  I just load up the measuring blocks list and pick it from the list.