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cleethorpes · Posted: Wed Mar 10, 2004 5:40 am Post subject: 944 intercooler install..

Does anyone have any info, site links with regards the installation of the nose mount intercooler?

Should be arriving friday, along with a replacement 944 fuel tank and filler neck(my tank is leaking like hell!).

Also anyone know where in the uk I can get hold of a replacement ansa exhaust. If not any other throaty number would do...

Cheers

Lizard · Posted: Wed Mar 10, 2004 5:45 am Post subject:

for a 944 install check out www.alexroy.net
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3 928s,

81turbo · Joined: 03 Nov 2002 Posts: 1065 Location: Oakland, CA

Lizard you are wrong, Alex used a Starion intercooler not a 951 unit.

Lizard · Posted: Wed Mar 10, 2004 7:30 am Post subject:

oh ok, thanx for the correct, havent checked in awhile
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3 928s,

cleethorpes · Posted: Wed Mar 10, 2004 8:59 am Post subject:

Cheers Lizard.

Looking at it. The install is near enough the same, the steel pipes would just need to be altered slightly to mate up with the 944 cooler.

Don't fancy that 'five pieces a bend welding' though!

Surely some decent quality ridgid rubber/plasti c hoses could be used. (assuming they don't distort under pressure that is!

I'm getting a few of the connecting pipes with the cooler so hopefully I won't need to fab up to much!!

Paul · Posted: Wed Mar 10, 2004 10:45 am Post subject:

The wife's Audi TT's turbo piping is mostly rubber looking hoses held by ordinary hose clamps. Its boost is almost instantly available so the hoses must not expand much.

Most cooling systems run 14 to 15 psi and 180 to 200 degrees, so once your a foot or 2 from the turbo IMO cooling system hoses should do fine.

cleethorpes · Posted: Wed Mar 10, 2004 7:45 pm Post subject:

Isn't the audi a low pressure turbo though?

I've got a 1.8t golf and I think thats a lpt...either that or it is a crap turbo!

Lizard · Posted: Thu Mar 11, 2004 4:39 am Post subject:

I think what you are talking about cleethorpes is the CFMs I am not sure that anyone here will know how many CFMs the 931 turbo pushes
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3 928s,

Alex Roy · Posted: Thu Mar 11, 2004 5:21 am Post subject:

It is alot of welding to do full metal pipes (though you do need some rubber or silicone hose between parts that will move/vibrate differently). It was the best option for me since I already have a MIG welder and I love working with aluminum, so I'll use any excuse. My pipe bender wouldn't bend tight enough for the first bend out of the turbo or the last bend into the intake, so I did a tight bend by first bending with the pipe bender, then sectioning and re-welding the pipe and then finally porting the tube out to make the inside a smooth transition.

I also used this method so I could keep the stock vacuum port location and the wastegate port location etc. If you are going to have your vacuum port and waste gate ports re routed then you can certianly just use reinforced rubber or silicone hose.

The silicone hose I use is rated to 300 psi (yep, that's what it says on it) and 350 degrees fahrenheit and is intended specificly for use in turbo/supercharger systems.

cleethorpes · Posted: Thu Mar 11, 2004 10:36 am Post subject:

top job alex!

Is the 944 turbo connection the same as the 924?

If so, I should be able to use the 944 pipe straight from the turbo then simply hack into it and go off at the angle I need....probably not as easy as that though is it??

By the way alex, tried welding new battery box and a few other bits on my old beetle..ended up just about doubling the size of the problem I was trying to solve...never again... was an arc mind, if I had a mig it may be a different story..

Alex Roy · Posted: Thu Mar 11, 2004 10:49 am Post subject:

The 944 pipes are nothing like what you would need to retrofit on a 931. It's going to be a fab job all the way. The hardest part is getting past the fuel distributor.

Keep in mind that I'm using a front mount Starion intercooler, but pipe routing should be nearly the same for a 944 unit, the difference being that the 944 unit lives behind the nose panel while mine is out infront of the car and fully open to air (and rocks and curbs etc)

Paul · Posted: Thu Mar 11, 2004 12:30 pm Post subject:

Paul · Posted: Thu Mar 11, 2004 12:43 pm Post subject:

Found it: 29 PSI in the wife's TT:

A Type K04 turbocharger forces air into the combustion chamber via two charge-air intercoolers. Compared to the less powerful 132-kW unit, a modified airflow path, together with a larger air cleaner, ensures that the air reaching the engine has a temperature only about 30¡C higher than ambient. This 80% charge-air intercooler efficiency keeps the engine supplied with an optimum flow of oxygen-rich air. Maximum boost pressure at the intake manifold can reach 200 kPa (29 lb/in2).

The higher-output 165-kW (225-hp) engine uses a high compression ratio (8.9:1) for a turbocharged unit. The 1.8-L engine was extensively modified to attain the higher output reliably. The pistons, connecting rods, and big-end bearings were uprated to accommodate the higher combustion pressures. The double-mass flywheel and clutch were modified to match the greater performance. The intake manifold, turbocharger, and exhaust manifold are new.

cleethorpes · Posted: Fri Mar 12, 2004 6:39 am Post subject:

my 1.8t is a pathetic 150bhp.. I guess I suffer from a low pressure turbo!