If you own a mk4 PD golf you are mostly likely aware of the restrictive piping/boost leak problems that the stock system holds. The tiny side mounted intercooler really struggles when you have the car remapped. On top of this I had several issues with the piping, namely with the pancake pipe constantly flying off.

I was looking for a fix for this; I researched long and hard on where I could get a suitable FMIC and a new piping system that would bring an end to these problems. As far as I was aware, Allard Motorsport was the only option, but after hearing several horror stories on how their intercoolers were a nightmare to fit, I decided to steer well clear.. Luckily around this time, Forge Motorsport became aware of the immense demand for this product amongst us dubbers and were on the hunt for a donor car to develop this FMIC..

So the car went in to the development manager at Forge, the aim being to fit an intercooler within the confines of the existing bumper and without compromising the integrity of the car, also with a view that probably 50% of the buyers will be fitting it at home so they couldn’t just crack out the plasma cutter!

A lot of progress was made in the first week as the intercooler was mounted and the new pipe run was put together. Now the core part of the intercooler was going to be the same as what was currently available for the Forge petrol FMIC, so in theory everything should have been ok.

However, then we realised perhaps why there was no product on the market for the diesel - on the petrols, the turbo is relatively towards the front of the engine but whereas for the diesel, the turbo lies towards the back of the engine making the pipe run from the turbo to the intercooler so much more difficult. Coupled with this, the biggest problem was the total lack of space to get any pipe work to the intercooler, furthermore the development manager was certain that the space behind the front bumper on the diesel was a little less than in the petrol, only by 5mm or so but this made all the difference when trying to mount the intercooler.

The standard bumper did need to be cut down, but only by a very minimal amount.. (pic to follow)

Eventually they did manage to make it fit and then testing began…

After three weeks of vigorous tests and extended development (and a lot of praying that it would work) finally we got positive results. Temperature levels had dropped considerably, from a peak of 60 deg C with the stock intercooler to a cool peak of 24 deg C with the Forge FMIC.  I’ve done around 750 miles since the intercooler has been fitted and the car is running fantastically well. First impressions are that it definitely pulls much more freely and is quicker from 20mph-80mph. There is also much more turbo whistle, this is probably down to the new pipe work, but it sounds great! Off the line, there is more lag, but only slightly, this is to be expected with a large FMIC.

I took a few pictures on the weekend, but there’s not much to see from the outside as most the piping is hidden behind the bumper. Also, I have a R32 front bumper, so the intercooler looks alot smaller, but on a standard bumper it fits complete flush with the lower grills.. It was far too wet, but if anyone wants I'll take whip the bumper off and get more pics..

Here you can see they have replaced the restrictive pancake pipe to a far superior design:

I have to say a big thanks to Peter and Chris Llyod at Forge Motorsport, fantastic service throughout the whole process, and kept me informed every step of the way. Could not recommend them enough! Also a BIG thank you Joe (afro_gti) on this forum, for giving me the heads up for this, I wouldn’t have had the opportunity to have this done if it weren’t for you so I owe you one mate..

Sorry for the long read, this has ended up being a lot longer than I thought lol.. but any further questions, please just ask and I’ll try answer.

The product is now on sale here: 

http://www.forgemotorsport.co.uk/content.asp?inc=product&cat=260302INT&product=FMINTMK4PD

 .. apparently forum members get a 10% discount..

Good write up

Well done,  forge products are quality.   The forge team have always helpful on the phone when i rang them

good review.

any use on a pd100? or do you need to be pushing serious bhp to get gains?

and what kinda cost are we looking at?

hotboy836:

good review.

any use on a pd100? or do you need to be pushing serious bhp to get gains?

and what kinda cost are we looking at?

ive added the link up mate..

you wont get any bhp gains, but the car does run so much better, its hard to describe, theres this added grunt and it just pulls so much better than it ever did before.. plus keeping the temperatures down is only a good thing...

depends if you suffer from heat soak? its quite cold now anyway but in the spring/summer it will definetley come in handy, its more useful if you are running bigger power obviously.. aint you going hybrid anyway hotboy

if you give me some money ill go hybrid...

 Looks totally AWESOME bro and your right it makes your car look a lot more agressive!

Your only one step away from realising your Hybrid dream man, get that turbo on

 looks good 

one question - is the EGR to intercooler pipe replaced or is the OEM just re-directed?

can you get us some pics of the top pipework run please mate?

not seen 1 single part of it yet! does it goe down the back of the headlight and then round the front to the core?

Top write up there!   by the looks of things plenty of good work by the guys at forge,

I've a couple of questions though if possible,

What are the dimensions of the intercooler?  As above what are is teh pipe work from the intercooler to EGR?

and where does the map senser plug in?

Sorry for all the questions

Greg

fenwick458:

can you get us some pics of the top pipework run please mate?

not seen 1 single part of it yet! does it goe down the back of the headlight and then round the front to the core?

From the first picture it seems to run in the bumper reinforcement channel Stuart

Then round through 180 by the looks as you can see it where the headlight is out.

Would like some better pictures though

Neil

 hey guys, I will follow the pipework and will try get some better pictures on the weekend, weather permitting..

Bump on the EGR.... is it replaced or remaining??

Chris.

Chris_Wales:

Bump on the EGR.... is it replaced or remaining??

Chris.

the EGR is still there.. but i'm on the lookout for an EGR delete to replace it..

 there you go

 any pics of the pipe work yet?

any dimensions or pics of the sensor location?

Cheers

Greg

 guys, i was in amsterdam all weekend, only just got back, so will try get a few pics with the engine cover off some time this week..

 the sound from the intercooler/pipework just gets better and better in this cold weather.. it makes (imo) a really cool darth vader type sound when you floor the throttle.. i love it!

just need the CAI back in to enhance the sound even more

if you wanna keep your engine you best stay away from them things.

hotboy836:

if you wanna keep your engine you best stay away from them things.

nooo.. im getting one without a low lying filter, like you say you cant be risking it..

 Here's full fitting instructions

http://www.forgemotorsport.co.uk/media/FMINTMK4PD.pdf

Forge Motorsport:

 Here's full fitting instructions

http://www.forgemotorsport.co.uk/media/FMINTMK4PD.pdf

this should help you chaps in the mean time whilst i get some pics, im impressed with the level of detail in the fitting instructions!

Looking at the fitting instructions, the only weak link left in the pipe work is the red pipe coming from the turbo.

I think SFS are designing a replacement  for this. 

Well design kit from Forge.

aRd:

Looking at the fitting instructions, the only weak link left in the pipe work is the red pipe coming from the turbo.

I think SFS are designing a replacement  for this. 

Well design kit from Forge.

I think with a standard turbo this red pipe is fine, but I am also looking at changing this to the SFS one when i go hybrid..

austin21:

What are the dimensions of the intercooler? 

Intercooler is 540x200x60mm

austin21:

 As above what are is teh pipe work from the intercooler to EGR?

You can make out the top pipe run here I think. Out of the intercooler into a coupler, into a 45 degree aluminium bend, into a 135 degree silicon bend, into the stock pipework. Its nowhere near the EGR !

Hope that helps?

Any chance of a few engine bay pics with the engine cover off?

aRd:

Looking at the fitting instructions, the only weak link left in the pipe work is the red pipe coming from the turbo.

I think SFS are designing a replacement  for this. 

Well design kit from Forge.

they were going to change this pipe too but it houses a built in restrictor of sorts so they didnt want to remove it.. this pipework setup should be good for 300bhp anyway..

azzle123:

Any chance of a few engine bay pics with the engine cover off?

yes il try on the weekend, but what bit exactly did you want to see?

I've studied it more carefully and think i know whats going on.

Cheers adz that's spot on. 

Hope all's still going well with it.

greg

austin21:

Cheers adz that's spot on. 

Hope all's still going well with it.

greg

No problem mate, anyone have any more questions just ask..

If I was completley honest, its just getting better and better, the darth vader type sounds the car makes when you floor it in second are SO addictive! and the car just pulls and pulls so much better than it used to! i love it! this mod is fast becoming one of the best ive done to the car!

adz2k6:

aRd:

Looking at the fitting instructions, the only weak link left in the pipe work is the red pipe coming from the turbo.

I think SFS are designing a replacement  for this. 

Well design kit from Forge.

they were going to change this pipe too but it houses a built in restrictor of sorts so they didnt want to remove it.. this pipework setup should be good for 300bhp anyway..

Why is this red pipe seen as a weak link ?

The fitting on the turbo on Adz car was very secure. Maybe the end that went into the stock pancake pipe is a problem (which we've eradicated). The turbo end of the pipe has a built in restrictor of sorts, i dont know what it was for, but its about 20mm thick with a small-ish (30mm?) hole through the middle. We didn't want to change the hose out for that reason.

 Has anyone bought one yet? It would be nice to hear from others how they get on fitting it.. I'll post up a pic of the internals of the standard bumper, it might help to compare so you can all see what bits have been trimmed..

I plan to....student loans ftw.

 azzle

when ur ready ...e mail me