Over the next days, I will install a 20x6x2.75 FMIC on our 1998 A4 1.8T.
The stock charged air runs from the turbo on the passenger side along the front to the intercooler on the driver side through a roughly 2" OD tube.

In the center of this tube, an engine mount is integrated into the tube.

Is it common to leave the entire tube in place (support brackets on passenger and driver side end) and install the new FMIC UNDER the tube, or IN FRONT of it?

My first idea to just take the stock tube out obviously won't work, unless the motor mount is not needed (I doubt it).

 

yea im actually doing the same thing i just bought this car and the previous owner ran over a guard railing ripping that metal piping connection between the turbo and intercooler, let me know how installing a front mount works out and what you did, i plan on installing this weekend or week as soon as it comes in

 

Well, I am 90% done. Here is MY experience:

I selected a 20x6 Godspeed IC, 2.75 thick. 2.5 inch in/out connection.
I went with 2.0 inch piping (according to Corky Bell, a 2.5 inch tubing is adequate (at 293 ft/sec air velocity or 0.27 Mach) for 600 cfm which equates to 400 bhp. Larger is NOT better (for example increased turbo lag from additional air volume that needs to be compressed). Glad I did (see below how tight it gets). My goal: 300 hp, therefore plenty of IC and pipe diam.

Here is a pic of the kit I bought:


The tubes shown are NOT actual for the A4 B5. There were 3 tubes, one for the driver side (from IC to intake hose), 2 for the passenger side (1x turbo outlet hose tube with 1" nipple for DV, 1x from there to IC with 1x 90 deg bend and 1x ca. 45 deg bend).

Problems:
- 2.75" is too thick. I had to cut the bumper/grind the bumper in 6 locations. Even then the IC is solid pressed against the A/C cooler.
- 6" height (the connectors are not symmetrical, I installed with the larger portion UP) is the max height to still fit UNDER the metal structure of the bumper)
- 20" wide works. If wider, the IC will interfere even more with the bummper (since it is curved, closer to car moving out from the center)
- 2" pipes are tight fit. Had to remove one horn on passenger side. Still solid pressed against the 2 A/C hoses on passenger side, against frame on driver side.
- pipe bends are not optimal, but can be forced to fit (with pressure on the silicone connectors; not ideal)
- 1" nippel on pipe requires extra hose to connect to DV (I have the ATP R1 valve)
- 1" nippel is 180 degree offset to the location of the DV (long hose needed AND has to make 180 degree bend without kinking!)

Mounting: The IC sits so tight, it is currently holding fine with just the connectors. I will use 2x 90 degree angles from Home Depot and bolt into the mounting points on top of the IC and to the metal of the bumper reinforcement, very simple.

Summary: I paid $300 on ebay for the kit. They first shipped a kit for a Passat. Then shipped with transition from 2" pipe to 2.75" IC. Bends are not optimal. Assuming that the kits offered by 'reputable' outfits for $1,000 fit perfect (yet to be seen/heard/proven), I still would trade the $700 for some elbow grease.
The cooling pipe loop (power steering?) I just bent up and zip tied together with the sensor to the driver side upper corner of the radiator.
Silicone connectors seem adequate.
T-bolt clamps work well.

Here are links to more pics from the install:

http://i853.photobucket.com/albums/a...4/IMG_4366.jpg
http://i853.photobucket.com/albums/a...4/IMG_4377.jpg
http://i853.photobucket.com/albums/a...4/IMG_4367.jpg
http://i853.photobucket.com/albums/a...4/IMG_4388.jpg
http://i853.photobucket.com/albums/a...4/IMG_4387.jpg
http://i853.photobucket.com/albums/a...4/IMG_4390.jpg
http://i853.photobucket.com/albums/a...4/IMG_4389.jpg
http://i853.photobucket.com/albums/a...4/IMG_4397.jpg
http://i853.photobucket.com/albums/a...4/IMG_4392.jpg
http://i853.photobucket.com/albums/a...4/IMG_4410.jpg
http://i853.photobucket.com/albums/a...4/IMG_4409.jpg
http://i853.photobucket.com/albums/a...4/IMG_4396.jpg
http://i853.photobucket.com/albums/a...4/IMG_4395.jpg
http://i853.photobucket.com/albums/a...4/IMG_4393.jpg

 

The Racetec kits are a perfect fit with very little trimming and you can get one of those for $800.

You might want to look into buying a Steering pump cooler, they are cheap and easy to install.

 

Isn't that the looped tubing? Then I already have one (sits above the intercooler/bumper), easy to relocate. Or are you suggesting to get rid of the stock one and get a custom one that can be located elsewhere?

If not:
- what is the looped tubing cooling for? Brake?

For someone who does not want to go through a bit of the headaches I described, paying the 267% price tag is sure an option.

I am just glad I did not go with the 'custom build' approach, because figuring out the bends with trial (measure, cut, tag weld, try for fit) and error would have been a nightmare, and likely consumed a lot of tubing. At $150 shipped for the IC itself, the 10 T-bolt clamps ($50?), 5 silicone couplers ($30), there is only $70 left for tubing; aside from having to find someone to weld the aluminum and the time for all this trial and error.

For me, it was the best cost/benefit ratio.

 

Yes the black U tube is the stock steering pump cooler, but it isn't doing much if it isn't in direct air flow. I was suggesting replacing it with a real cooler.

Like this one on my car.

 

Nice! Mine is hanging in the top right corner diagonally, so it IS in the flow.
What happens in normal driving it it won't cool enough (I am not talking street cross racing)?

Just trying to avoid more piping/hose/connections work if I can.
Did you have the license plate made in Germany? Does the standard size (Germany/EU) plate fit?
What bumper (year/model) is shown?

 

there are numerous sites to buy plates, that is an s4(rs4) bumper....they fit right in....as for the "motor mount" that is your snub, replacing that eventually is a good thing, but keep the factory ic tube as part of your core

 

Yeah the bumper on my car is just your standard B5 S4 stock bumper, it has a spot to mount a Euro plate.

Picture back when I first out it on.


Picture taken last year.

 

I get more satisfaction out of fabrication...it may be a pain to do the pipes yourself, but its a small price to pay for some independence and bragging rights Looks good man. Mike, so jealous...