How-to flow more air to the Intercooler on the Passat - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 2 (permalink) Old 10-10-2005, 08:41 PM Thread Starter
 
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How to flow more air to the Intercooler on the Passat

The intercooler on the TDI Passat is in a rather restrictive and useless location though if you are willing to give up the mediocre factory driving lights you can flow a lot more air to the IC.

Simply:

1. Pop out the black trim piece around the DL
2. Remove the DL with a Phillips screw driver
3. Take a pistol grinder w/50 grit to the back of the trim piece where you want to remove plastic.
4. When you start to see the outline of the desired opening stop grinding
5. Take a utility knife and cut along the opening outline
6. Remove desired bumper plastic on the very right side of the opening with a Rotozip, air recip saw or a very sharp utility knife.
7. De-burr as you wish but remember its a drag car not a show car.
8. Install the black trim piece onto the bumper.
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post #2 of 2 (permalink) Old 10-10-2005, 08:48 PM Thread Starter
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For all practical purposes you could easily remove the LH light to race or dyno then re-install it but I don't feel your missing much without it.
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