I started off with some research on the net which revealed such systems have been used since quite some time back. The poplularity of doing such a mod fell away after the introduction of WMI kits though. I have never been a fan of WMI after hearing and reading too many bad things. Im not saying they dont work it just would never make my wish list. Keeping intake temperatures down is a priority though, hence the intake heatshield, ram air tubing and cold air cone enclosure.
A few guys have installed intercooler sprayers onto their G5 GTIs using the original windscreen washer bottle and pump. One issue raised in some threads about such systems was the "sandwhich" type setup the 2.0TFSI motors have. The intercooler is inconveniently located between two other radiators. Some guys located the sprayers infront of the front radiator in hope that the airflow would carry some spray through to the intercooler. To get maximum cooling effect I wanted to spray directly onto the intercooler.
I bought some regular garden sprayer nozzles, t-pieces and ball valves from the local hardware store. I had silicone boost pipe and the handy cable ties in stock in the garage. I ran some quick tests using a conveniently located pipe on the bonnet to test my nozzles and pipes. I found that using the standard pump on the washer bottle that two nozzles gave the best mist type spray that travelled a fair distance. 4 nozzles did not spray as far and had bigger droplets. The finer the spray the more effective cooling is achieved. This is due to the increased surface area of the water droplets and hence heatflow once contact is made between the hot intercooler and the cold water.
The front bumper removed:
With the bumper removed I had full access to the radiator and intercooler sandwhich to place the nozzles strategically.
The headlight washer needs to be disconnected from the washer bottle to remove the front bumper. The bucket was used to collect the washer fluid.
The LC's face(off):
Washer bottle and pump:
Facing the front of the car the outlet on the right is for the rear screen spray nozzle. I chose this as activating the pump activates the wiper and the rear wiper going off would be less distracting than the front wipers.
On/off valve and T-piece:
I installed on/off ball valves to control where the flow would go. Using the silicone boost pipe i made a T-junction which would go to the intercooler sprayers and the other would join back to the original screen sprayer pipe.
Nozzles:
The boost pipe coming from the water bottle is split again to take water to each nozzle. Holes were drilled into the plastic above the intercooler to mount the nozzles. Hard plastic garden hose and some modified (blocked off) t-pieces were used.
Right Nozzle:
Left Nozzle:
Intercooler Sprayers on/off valve:
I have access to switch both on or off by removing the fog light cover. I can have all spray go to the intercooler, or all to the rear screen or by having both valves open share the spray between both.
Mounted piping:
A few guys have installed intercooler sprayers onto their G5 GTIs using the original windscreen washer bottle and pump. One issue raised in some threads about such systems was the "sandwhich" type setup the 2.0TFSI motors have. The intercooler is inconveniently located between two other radiators. Some guys located the sprayers infront of the front radiator in hope that the airflow would carry some spray through to the intercooler. To get maximum cooling effect I wanted to spray directly onto the intercooler.
I bought some regular garden sprayer nozzles, t-pieces and ball valves from the local hardware store. I had silicone boost pipe and the handy cable ties in stock in the garage. I ran some quick tests using a conveniently located pipe on the bonnet to test my nozzles and pipes. I found that using the standard pump on the washer bottle that two nozzles gave the best mist type spray that travelled a fair distance. 4 nozzles did not spray as far and had bigger droplets. The finer the spray the more effective cooling is achieved. This is due to the increased surface area of the water droplets and hence heatflow once contact is made between the hot intercooler and the cold water.
The front bumper removed:
With the bumper removed I had full access to the radiator and intercooler sandwhich to place the nozzles strategically.
The headlight washer needs to be disconnected from the washer bottle to remove the front bumper. The bucket was used to collect the washer fluid.
The LC's face(off):
Washer bottle and pump:
Facing the front of the car the outlet on the right is for the rear screen spray nozzle. I chose this as activating the pump activates the wiper and the rear wiper going off would be less distracting than the front wipers.
On/off valve and T-piece:
I installed on/off ball valves to control where the flow would go. Using the silicone boost pipe i made a T-junction which would go to the intercooler sprayers and the other would join back to the original screen sprayer pipe.
Nozzles:
The boost pipe coming from the water bottle is split again to take water to each nozzle. Holes were drilled into the plastic above the intercooler to mount the nozzles. Hard plastic garden hose and some modified (blocked off) t-pieces were used.
Right Nozzle:
Left Nozzle:
Intercooler Sprayers on/off valve:
I have access to switch both on or off by removing the fog light cover. I can have all spray go to the intercooler, or all to the rear screen or by having both valves open share the spray between both.
Mounted piping: