Mk1 golf AGU 1.8T coversion - Intercooler and wiring ???

Firstly ive been looking for intercooler setups, ive found one on ebay which appears to nicely fit between the rad and front grill and comes out the sides of the rad, it claims its a good conversion for what im doing, but the id is 57mm and the AGU is 63mm. one would assume the clamping effect of the hose would compensate for this 6 mm difference, anyone ????

From anyones experience what is the best setup up for hoses, elbows and pipes to join the intercooler ? or is it trial and error. i just dont want to buy loads of pipes and hoses and not need barely any of it, seems like a waste of money as im reaching my budget.

Lastly reading through everyones wiring to incorporate the agu loom into the fuse box sounds very confusing. Reading through the mk4 golf haynes explains it so much better and makes me feel more confident on the job ahead. Can you not just run the relevent feeds to the ECU seperately using ignition switched relays.

should be getting my engine through on tuesday so hopefully it should shed some light. as all i have to sort out now is the intercooler/pipes and getting the immob removed from the ecu as im using oe setup.

If various sensors will be left disconnected from the engine the car wont go into limp mode will it ? as limp mode only really effects the actual running sensors of the car ie camshaft sensor/coolent temp? can any one agree with me

thanks

Do you mean id and are you worried about the step between intercooler and throttle body and any flow problems or do you possibly mean od and are concerned about the hose fitting different sized ends, if the former i dont think its a problem as the flow is from intercooler to throttle body.

intercooler side of things ill be able to sort out once i have the engine, i was just wondering what extra hoses/pipes ill need.

Any thoughts on the other things?? thanks

Somewhere in the boost piping you'll use a reducer pipe to take the Id down when you connect to the cooler.

I did this when piping my g60, my tb is 60mm and I used reducers to bring the piping down to 51mm for my cooler.

An example
http://www.regals-motorsport.co.uk/silicone-hoses/90-degree-elbow-reducer/black-63mm-57mm-id-90-degree-elbow-reducer-silicon-hose-p-8605.html

Basically, I used an eBay intercooler, without piping kit, as even with a piping kit, you wouldn't use half of it! The core of the intercooler I got is 550 x 140 x 65 mm then bought a length of 1m 57mm polished alloy pipe, one 57mm to 51mm reducer to go from the intercooler piping to the turbo, two 90 degree elbows to go from the back of the bay to the front of the bay and connect to the cooler both 57mm, then one more 57mm elbow to go from the other end of the cooler towards the inlet manifold, then an alloy T piece to take the DV off it, then one 63mm elbow to connect that to the inlet manifold. Like you said, I am hoping that the 63mm one can be clamped over the 57mm pipe, which I think it will but I am not sure on this year, so don't take my word for it. I will report back once my piping is in.

I hope that helps.
Joe

Oh, plus you need a good few hose clamps, two per connector and don't get jubilee clips, they will not hold the pipes properly and cause leaks and boost pipes to come off, so spend a little more and get proper silicone hose clamps.

Thanks thats really helpful

Im having a few issues with this too.

Dont want to start a new thread so my problem is that i have an intercooler basically in the grille, roughly centre and pushed as far forward towards the grille as i can get it, now if i put the rad in the standard plcae ( i think i have a nissen 1.8 gti rad) the hose would foul on the inlet manifold.

so what other rads have people used and are there any with the ends either facing inline with the rad rather than at 90 degree or one which has both outlets on the gearbox side?

Its that or payign for a custom one which i dont really want to budget for.

i used a mk2 16v fits perfect

or if you want to get rid of the coolant expansion tank altogether for a cleaner look, you can go with a mk1 1.5 radiator which has a built in expansion tank. That's what I went for, it's big block too so will cope with the heat of the 1.8T

A few others have done the same. It has both inlet and outlet on gearbox side.

the guide also says mk2 16v rad fits fine

On this picture it shows the rad in no prob ( this aint mine but my intercooler is in the same position.

My AUQ engine has a bracket and pipes surrounding the dipstick so this limits the space too, thats one of the reasons i thought it would foul if the radiator was put in its standard place.

scotty_82 said

On this picture it shows the rad in no prob ( this aint mine but my intercooler is in the same position.

My AUQ engine has a bracket and pipes surrounding the dipstick so this limits the space too, thats one of the reasons i thought it would foul if the radiator was put in its standard place.

hi there..what pipes did you use for the radiator..im just a bit stuck.. thanks ben

them pitures are of my golf im doing the top pipe for the rad i took of a mercedaes from a scrap yard forgot what model now. bottom pipe was a mk2 16v i think . i removed the bracket by the dip stick and move the dip stick into the tb hole