BIG POWER MODS! Front-Mount Intercooler to a 1.8T Mk4 Golf!

We're getting closer to remapping the Golf, and one of the bolt-on modifications required for a stage 2 map is a front-mount intercooler, to replace the standard side-mount.
This allows denser and cooler air to feed to the manifold/turbo, allowing bigger and safer figures when it comes to mapping!
The kit I got, came with a Toyosport 220mm core, with custom 2.5" hardpipe and silicone tubing, but as you can see, not much of that was left in!
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[@BWTV]

Oh just ignore the "down down" mistake at 6:10 lol

[@cjay1348]

BWTV when are u getting the golf mapped

[@SizeableBush]

That guy sounds like a proper road man 🙌🏻💪🏻

[@TheRaceAcer]

i pulled ovoh. He sounds even more Manc than i do :P

[@shiftinggears9896]

That turbo fluttering you're getting could be that there is a leak in the pipe which goes from the top of the Dv to the wastegate actuator. I fitted a 3inch intercooler pipe kit and welly cooler. After fitting it i reved the car up a few times and got that fluttering sound.. Looked over my work and noticed I hadn't put the hose properly on the dv.. Pushed it on and fluttering sound went.. So you could have a. Leak in that pipe.

[@jxckc351]

turbo flutter. sounds good, it's will not damage the car in anyway

[@craigwishart5559]

enjoying all your vlogs, keeping my motivation and getting inspiration from you.... thanks man

[@boytoy663]

"transverse engine so it sits longways in the bay"...pretty sure thats longitudinal

[@insidebyte8561]

That turbo sound is the air going back through the turbo the wrong way so you need to look at getting a bigger dump valve :)

[@Just_James_79]

The turbo flutter will be from the kinked pipe he mentions going to the diverter valve

[@rsyt3113]

Looking forward to your new series mate, that intercooler looks mad 👊🏻👌🏻

[@BWTV]

Cheers man! 👌

[@TheRaceAcer]

great job mate, looks shite when the pipe elbows are sticking out the front bumper

[@BWTV]

SecondGear yeah that was the number 1 thing we wanted to avoid 😂

[@apextos81]

Have you disconnected the recirculation valve? How is it fluttering like that?

[@jjoocckkeess]

Is it making more power with fmic?

[@tdiarosa]

Who’d you get to make the custom pipework?

[@nomessininc.]

Coming along nicely bro 👍

[@BWTV]

CATALYTIC UK Cheers man 🤙

[@osamas3]

Great videos! Though, I've been meaning to ask, since I want to replace my tail lights, are those M3 style DEPO smoked taillights? I can't find any videos of them in the dark, besides yours in the drifting video.. So do those "M3 like" stripes, look decent or not really worth it? Because I'm thinking about getting these tail lights for my golf.

[@gamster2968]

Amazing job well done I love your car mate

[@BWTV]

Gamster 29 thanks man! 👌

[@gamster2968]

BWTV your welcome

[@obscureperformance1242]

Good job on that, better than half of them that have the bull bars sticking out. Map it!

[@BWTV]

mk2bunny Cheers mate that was our main concern 😂 oversize tip and a new fuel pump and it will be ready 🤙

[@obscureperformance1242]

Yours got a KO3 or KO3S?

[@BWTV]

mk2bunny ko3s 👍

[@obscureperformance1242]

Nice, hopefully see it around 240ish, hope you're going to rtech!

[@andrewwright.]

Want to make that golf move? Look into ko4-001 straight swap for ko3 and will give more power up top. Tuned right it would sit around 260

[@BWTV]

That's tempting, but my standard clutch would be f*ked right? I'm gonna get it mapped how it is and then change the clutch and flywheel 👌

[@callumhanson8126]

My dad's is 270 hp to engine and like 180-220 to wheels it got mapped ages ago

[@callumhanson8126]

We might be getting spark plugs and a air filter soon

[@callumhanson8126]

It's a gti mk4

[@andrewwright.]

BWTV stage one ko3 map could show a bad clutch but a good tuner can cap off torque and give you time to replace the clutch, go back and turn up the boost.

[@jbl6200]

any chance you remember where u got ur pipng from? as I cant seem to find anything bigger the 2" pipework?

[@juliusgovers772]

Where did you get the intercooler.

[@Leatherkid01]

Nicely done.... Does nathan have a channel?

[@callumhanson8126]

It's sounds better my opinion

[@4nish1993]

What diameter is your intercooler piping?

[@mk3caddy100]

hi mate how much for all that work

[@MarkSmith-ze8xt]

How come you have a constant Engine Management light on ? Please explain dude keep up the great videos ... try and collab with someone who has a 1.9 PD TDI ?

[@BWTV]

Things like the thermostat has been broken since owning the car which causes the light to appear. Got quite the few codes show up also because of the decat and SAI, n249 delete 👍

[@plamen_m]

Hi, nice video man. do you have any errors on ecu after taking secondary air pump out and any boost leak (very common problem ) ? :)

[@BWTV]

No boost leak but plenty of codes 🤣

[@stevecvntniko8271]

Heaps of codes on mine weekly

[@huwjass80]

I cut the plugs off on mine and wired in some 33ohm resistors to trick the system. You can buy the dead end plug resistor kits off eBay but I did it the tedious way, "no warning lights on dash" 🙌🏻 (running rich as hell though untill I get it mapped)

[@johnstokes3232]

U should put a oversized tip on next get the car breathing more 👍

[@BWTV]

That's next 😉

[@jamesrichardson4604]

Nice job mate , I've got mk4 gti turbo that i have owned for 14years . Just put a k03s hybrid turbo on it , making about 300bhp know . just subscribed mate.

[@BWTV]

Awesome man, I'll probably be going the hybrid route in the future. Cheers for the support! 👌

[@CalMUK91]

Needs mapping badly mate, I wouldn't be hammering it until its done really.

[@wazmru]

Well said.

[@BWTV]

Yeah I just want to get everything done before mapping, don't want to map it then 2 months later I buy a bigger TIP, just trying to get everything done for it now 👍

[@nathanjimenez4176]

Hey I have a 1.8t and I was wondering (for anybody that has a mk4 1.8t or any turbocharged car) would a blow out valve be a good idea to do?

[@olskoolbandito]

Nathan Jimenez nkt a good idea m8..u need to keep a dv valve...not to atmosphere but one that recircs the boosted air (once throttle is closed) back into the inlet manifold ...otherwise the car will run wrong fuel/air ratios...

[@iMann_iFail]

The chatter noise is the turbo stalling.

[@doder67]

I dindt really get the love having an injector leaker? Was it cause of the MPG? :D

[@BWTV]

Yeah recently the mpg has been really low. Hopefully replacing the seals on the injectors will fix that 😁

[@doder67]

BWTV ah ic ic, overall great video tho! I have a mk4 myself and absolutely loving it :D its a 1,6 but its quite quick

[@TheRaceAcer]

even the 1.4s aren't too bad if it's the 16v version. Managed to squeeze 120mph out of one before which was also top for the 1.8t (blown turbo and 200,000+ miles)

[@ashhaque9352]

💯love it

[@BWTV]

Cheers man! 👌

[@wazmru]

How did you find out by yourself you got an injector leak ? What symtoms are you having and did you even scan and check flow rate on diagnostics computer ??

[@BWTV]

Very lumpy cold start, and I could see the fuel leak on the manifold, also the sh*t MPG. Sorted them now 👍

[@wazmru]

BWTV how did you see the fuel leak on Manifold ?

[@BWTV]

Coming out the injectors

[@Shakzey]

Longitudinal (however its spelt) not transverse lol

[@arinhos100]

where did you get your rear bumper from? props from Jersey CI

[@ouncy]

Toys r us.

[@BWTV]

I got it second hand but take a look on srs.tec, they sell a ton of varients. Only issue is delivery is quite expensive.

[@riapoer.6170]

Was the intercooler the reason for the stuttering of the turbo? I want that too man😁

[@riapoer.6170]

And where did you get the kit from?

[@TheRaceAcer]

it does help but all you need if to take the vacuum line off the BOV or change the BOV to an adjustable one so you get flutter on low boost and your normal woosh on high

[@BWTV]

Philipp Rittberger Yeah it started once fitting it, but I've heard non stop that it's not suppose to sound that way so I'm a little worried 😂 and the piping was custom made from a guy on the 1.8t tuning facebook page 🤙

[@riapoer.6170]

Looking forward to make this on my mk4 1.9tdi Thanks guys

[@TrainWarrior]

I'm pretty sure that stutter is air being forced back through the turbo. My 1.8t makes the same sound because my diverter valve is bad so the air from the turbo has nowhere to go but back through it. The only side effect is the sound, I haven't lost any boost. Some people say it could damage the turbo, but really only over the long run. You might want to replace it with the 710n DV or Forge DV. Coulda sworn you had the Forge DV though, what happened to it?

[@TheMidlandAngler]

Good stuff mate- if I was you- and my plans, although mines already remapped and is quick- go to BEACHBUGGYTURBO.co.uk these guys make serious turbos, my neighbour’s mk4 has the K300 turbo, then get it mapped at Rtech- his is pushing out 318bhp on his run after map 😜😎 I’m saving for one now amongst constantly buying other bits for my mk4 gti lol😅 Keep more vids coming anyway mate 👊🏼

[@BWTV]

Dman C888 I've heard of them before, definitely gonna look into it! 😋

[@christopherwoodhead7021]

I would have kept the stock cooler. I'm sure with data logging, it would have shown it to be better then a cheap cooler. There is a reason manufactures and motorsport use tube and fine and that's down to not getting thermal loaded like a bar and plate cooler and its ability to discharge heat fast.

[@BWTV]

Christopher Woodhead it's been proven a front mount is a huge benefit and significantly reduces heat soak, and the bonus 2.5" piping is even better. Which is why it's very common 😛

[@christopherwoodhead7021]

BWTV I know a good front mount like Pro Alloy gives great results. The stock cooler is front mount but is side mounted. 2.5” longer tube increases turbo lag as it has to fill that volume up first and the k03 does not have enough flow to take advantage of that extra size.

[@shiftinggears9896]

That's bollox there is nothing wrong with running 2.5inch or even 3 inch lol the lag you're talking about is minimal. decreased temperatures will make better power numbers.. And once mapped his motor will come onto 20-21psi and probably hold 19ish.. It will peak that at around 2850rpm and hold it till near redline aslong as he has no boost leaks..

[@Bmw116df20]

nicee 😁

[@BWTV]

Golf R Thanks mate! 😁

[@And1roidHD]

if u guys what the see more pics of the car at 0:09 sec instagram.com/curry32r is a mad car

[@Ben-us2ve]

She sounds like a beast 😍

[@BWTV]

Ben She does 😎

[@mechatroniker3061]

Gute young