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If you do not know how to, or are not comfortable with, removing your front bumper, then I'd advise against attempting this yourself.
If you are pretty familiar with the car, and not afraid to take some stuff apart, you will be good. I won't go through the whole install, but I'll give some tips on points that I had trouble with. Mine have been shaved so I didn't need to worry about it.
Next, remove the wind deflectors. The directions said there was a screw for these, but I didn't find one on mine. It just held in place by some pop in clips. This piece runs from below the foam bumper support, to behind it, to on top of it. I literally just grabbed the top of it, and broke it off with brute force, then broke the bottom part off, and wiggled all the pieces out.
You won't be reusing them. Then you have to move your horns. There is one on each side of the bumper. Literally just grab the horns, and bend them straight up. That's all you have to do. After that, install the core per directions. Then undo your stock intercooler hoses Now comes the tough part Trimming and Fitting the hoses.
What a nightmare. Mount your hoses and eyeball the excess hosing you have Re attach your hoses and see if they fit. I used a regular razorblade, which was a bit tricky. If you have a nice and sharp Exacto Knife, I would suggest you use that. Pro-Tip: When putting the couplers onto your new intercooler pipes, make sure the 2 "teeth" on the couplers are directly on top and below It took me 20 damn minutes to figure out this was the reason my couplers weren't mounting into the discharge pipe.
The passenger side isn't too hard, as it's only two ends getting mounted. One to the intercooler, one to the turbo discharge pipe. The Driver's side one is the nightmare, since it has 3 points that attach.
You will only need to trim the FMIC end, and the middle opening. The problem with this pipe is that if you hold the pipe up to the mounting points, it appears you need to trim all 3 ends, and that is an illusion.
If you are DSG, you will end up trimming down that middle piece quite a bit to get it to fit right. The best way to attach this hose, is to mount the Throttle Body Pipe End one first. Get it on fully, and then you can rotate the hose upwards and easily connect your middle coupler, and put the locking bracket over it.
Then force on your FMIC end, tight everything, and you are done. I have some pictures that I will upload later on to give you guys a better Idea about some of the things I was talking about. I hope these tips help other people out. Last edited: Jun 22, CJBarton Ready to race! Location Atlanta, Georgia. Im installing mine on Wednesday.
How long did this take you to install? Location McKinney, TX. You would think they would just make correct hose for the IC. I had to trim mine when I did it almost 6 years ago. I kept it on the car for maybe a year. CJBarton said:. You must log in or register to reply here.
DIY: Forge Twintercooler Install
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Thoughts on the Forge Twintercooler
Contact us to ensure you're getting the right part for your car at the absolute best pricing on earth! Moving on from our tried and tested Twintercooler setup on the Mk5 and Mk6, this intercooler has been designed to run in parallel with the stock core, or if you prefer for the ultimate cooling solution you can use it with our FMMK7FMIC intercooler which mounts in the stock location and offers much improved cooling by itself. This core is absolutely proven on road and track cars and continues to be an excellent and worthwhile addition to a stock or tuned VW. Proven data on dyno and road shows that the twintercooler core by itself with no other modifications gave a huge 20 deg C 69 deg F drop in temperature. Comparison runs were carried out on the same day on the same dyno and in ambient temperatures of 6 deg C 42 deg F. No bumper modification is necessary to fit this intercooler. All parts needed and full instructions are included.
Forge Twintercooler Installed!