OK today I have installed and S3 alloy intercooler, so I can go Stage 2+...
The APR guide is invaluable, just a few things;
The bottom screws for the grill are T20 not T25...
Think atep 19, the screws are T30 not T25...
Bag and label all screws, this is the best way to keep track...
Make sure the two prongs sit in the grommets and the top/side mounts slot in the cage and screws go in ok
The GTi hoses are easily modified with a hacksaw blade, cut in 3 places and bend back, take care so not to cut the rubber surface, if holding in a vice and cutting at the top, the alloy will split before going in to the rubber if you cut evenly...
Clean or replace the seal for the connector into the discharge pipe.
The inlet pipe hose goes straight on if you modify the pipes the way i did...
The discharge pipe hose needs to be trimmed to get the angle right, about 5mm off one side...
Found the slightest trace of oil in the hoses, but believe this is normal - as the lowest point off the system and oil vapours being drawn through it collects here.
Take your time, be methodical, tick off each step as you go, and note the APR is not so detailed on the refit stage.
The connectore plugs are easier to remove if you push them on first before pressed the clip.
This is a manageable one man job... I have proven that.
Some pics from the install...
Saftey first, car jacked up...
All apart... what have I done!?
Difference in coolers...
Carefully in place...
Front end ready to go back on...
Followed the APR guide but still numbered and labelled every set of nuts/screws...
MOdifying the pipework...
Pipes ready to go back on...
Hoses all clamped up...
All back together... *PHEW*
Hope it was all worth it when I go stage 2+, uploaded setting and sure it's more responsive and pulls harder already...
