Make a donation

Author Topic: Intercooler recommendations for a K04 conversion  (Read 374 times)

Offline ZoliWorks

  • Always Involved
  • ****
  • Thank You
  • -Given: 3
  • -Receive: 9
  • Posts: 82
Intercooler recommendations for a K04 conversion
« on: June 30, 2024, 11:58:57 pm »
Ever since I first mapped the car I felt like it always pulled better after it just got up to operating temperature compared to how it pulled after driving around for a bit. Well today I decided to log it again but this time included intake temps as well. surprise-surprise, it's not looking good. I guess that's what happens when you did a K04 swap, kept the stock intercooler and haven't yet replaced your leaking AC radiator that's bent up like hell.

So anyway, looking for suggestions on what IC to go with. I've been looking at the Ta-Technix cooler since I got both the downpipe and air intake from them. I've got no issues with those so far but I know (and knew from the start) that they are the same things you can find on Aliexpress but priced a bit higher. I was gonna order both the downpipe and intake from Ali, because I saw the exact same items there, but Ta-T did a sale and it came out cheaper than Ali.

https://www.tatechnix.de/tatechnix/gx/product_info.php?info=p37413_ta-technix-intercooler-kit-suitable-for-audi-a3-s3--8p----tt--8j----seat-leon--1p---skoda-octavia--1z---superb--3t----golf-v-vi--1k----jetta-iii-iv--1km-16-16h----eos--1f----passat--3c-3cc----scirocco-iii--13-.html&no_boost=1

Both of these logs come from the same pull. I went on the highway, made the first pull on the on ramp and the second after driving to a U-turn area that's 5km from the on/off ramp.

Ambient temp was 23 degrees here



Ambient temp was 20 degrees here


« Last Edit: July 01, 2024, 12:03:27 am by ZoliWorks »
Mk5 Jetta 2.0 TFSI BWA | Mk6 GTI Front | BorgWarner K04 Turbo | Ta-Technix Air Intake | Ta-Technix 200 Cell Downpipe | Stock Intercooler | Stock Injectors | Vis Motorsport 175 bar HPFP | 300hp


Offline mjmallia

  • Won't Shut up.
  • *****
  • Thank You
  • -Given: 2
  • -Receive: 48
  • Posts: 588
Re: Intercooler recommendations for a K04 conversion
« Reply #1 on: July 01, 2024, 09:12:22 am »
What have you got on at the moment.

The original GTI/Ed30 one is not great to be honest.  I changed mine to the later revised (non alloy ends) Golf 6R/TSI/S3 8P intercooler and noticed a vast improvement.  It is deeper, has a more efficient core, and fits perfectly while also deleting the old bayonet hose connectors that leak boost.
« Last Edit: July 12, 2024, 08:48:14 am by mjmallia »
Mike

South Coast

S3 8L ---- Golf Mk4 GT TDI ---- Lupo GTI ----  A4 B6 Sline ---- Golf Mk5 GTI

Offline mjmallia

  • Won't Shut up.
  • *****
  • Thank You
  • -Given: 2
  • -Receive: 48
  • Posts: 588
Re: Intercooler recommendations for a K04 conversion
« Reply #2 on: July 01, 2024, 09:14:03 am »




Mike

South Coast

S3 8L ---- Golf Mk4 GT TDI ---- Lupo GTI ----  A4 B6 Sline ---- Golf Mk5 GTI

Offline ZoliWorks

  • Always Involved
  • ****
  • Thank You
  • -Given: 3
  • -Receive: 9
  • Posts: 82
Re: Intercooler recommendations for a K04 conversion
« Reply #3 on: July 01, 2024, 09:37:48 am »
Mine is stock, like base model stock. Plastic end caps, quick connect hoses. and the AC radiator's fins are all bent up so basically no air is passing through it. I'm surprised my car isn't overheating...

I'm replacing the AC rad cause it's been leaking since I got the car so while at it I might as well do the intercooler.
Mk5 Jetta 2.0 TFSI BWA | Mk6 GTI Front | BorgWarner K04 Turbo | Ta-Technix Air Intake | Ta-Technix 200 Cell Downpipe | Stock Intercooler | Stock Injectors | Vis Motorsport 175 bar HPFP | 300hp


Offline pudding

  • Global Moderator
  • Just look at my post count
  • *
  • Thank You
  • -Given: 2
  • -Receive: 680
  • Posts: 8296
Re: Intercooler recommendations for a K04 conversion
« Reply #4 on: July 06, 2024, 12:26:55 pm »
I used the 6R intercooler as well. It worked great on my Edition 30.

The cooler bolts right in and you either need the 6R/S3 intercooler hoses as well, or you can cut the bayonet fittings off the original hoses, but I found the 6R/S3 hoses were a much better fit.  They can be had for peanuts off ebay used.

My A/C condenser was almost completely plugged so I replaced that as well and averaged 5 degrees above atmosphere over winter, and 8-10 over summer.  Much faster recovery rate than the stock GTI intercooler.

The ECU doesn't start pulling timing until intake temps hit 45 C, so your readings aren't too bad to be honest.

I prefer the OEM intercoolers as they balance the lag to cooling efficiency compromise pretty well, and it is the one they fitted to K04 engines, so you can't go wrong.


2007 ED30 | 2009 TDI 140 | 2016 BMW 330D

Offline ZoliWorks

  • Always Involved
  • ****
  • Thank You
  • -Given: 3
  • -Receive: 9
  • Posts: 82
Re: Intercooler recommendations for a K04 conversion
« Reply #5 on: July 09, 2024, 09:35:23 am »
I've replaced my AC condenser with an NRF brand unit a week ago as it was clogged and leaking. The AC system still doesn't seal perfectly but holds a steady -28 bar vacuum when we tested it. Good enough.

I feel like the newer gen S3 cooler still won't be enough. Even tho right now the car only makes 300hp, I do plan on fitting the proper S3 injectors and pushing that to 340hp. While it's unplanned right now, sometime in the future, when I'm done with everything I've planned for this car, I may end up forging the rods and pistons to fix the oil consumption issue these cars have and to make the engine safe for more power. I might get a bigger turbo, like one of those BOSS 500 kits. The S3/6R cooler might be too small then.

Regarding lag, how noticeable would you say it is on a bigger cooler? I dont really push the car sub 3k rpm cause it's not a K03 and it's outside of its efficiency zone.

Lastly, would you say you've noticed any improvement during casual driving when it's hot outside? I dont do track days or race with the car, I just do some pulls and floor it every now and then when driving from A to B.
Mk5 Jetta 2.0 TFSI BWA | Mk6 GTI Front | BorgWarner K04 Turbo | Ta-Technix Air Intake | Ta-Technix 200 Cell Downpipe | Stock Intercooler | Stock Injectors | Vis Motorsport 175 bar HPFP | 300hp