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Extra DSG oil cooler

43 views 2 replies 2 participants last post by  nigh7swimming  
#1 ·
(Something I did a year ago but didn't have time to post. Well if it lasted a year then it's probably solid enough to share..)
The general ideas behind my setup were:
  • add extra oil capacity (heat soak)
  • make the extra circuit optional and only use it when it's needed (above 75C or so)
  • mount the radiator as low as possible, and route the pipes such that any air pockets would naturally disperse (NRV helps)
  • have an active preview of the oil pressure off pump (pressure sender)

My choice was this:

Oil pump is Mocal EOP2 external gear pump. It's connected by a relay to a 7.5A fuse (nr 10, row 1, electric seats, which I don't have) and a cabin switch so I can turn it on/off even while driving.
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I called Mocal twice to consult my setup with their engineers.
I also bought an extra oil filter from them.
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There are other kits available which replace the collant-oil interchange radiator instead.
They are good but the issue with them is, they make DSG oil warm up slower on cool days and that's an issue in normal driving.
If mine was a track-only car, then it would probably be better (and simpler, lighter) but it's not the case for me. I need the best of both worlds.
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I mounted the radiator to the crash bar with 4 rivnuts, strategically placed. Then a custom aluminium harness and a wire mesh to protect it from road projectiles.
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All the hoses are AN8, braided and with extra sleeve to prevent any rubbing.
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The pump is mounted to the frame with metal tape and rivets, cable ties just as a fail-safe.
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Tricky bits:
  • tightening the AN fixings so they don't leak
  • cutting the hoses and making the fixings - a whole separate story..
  • routing the hoses in the tight space I have

One of the issues is, the car also has custom brake cooling ducts with electrical valves, extra air ducts off the (deleted) fog light inlets and the bumper has extra reinforcements for the custom splitter I made earlier. There's literally no space left in the front now!
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All installed by myself on a driveway except for the DSG cover which I asked my trusted mechanic to replace while doing DSG oil change. It was a first for them, as you can imagine. The procedure is mostly standard except an extra step: "you see that switch ? yeah, turn it on while setting the final oil level, before putting the plug on." They used around 7L of oil, but mind the radiator was primed by me earlier while testing.

The photos are mostly self-explanatory. I didn't take a dashboard photos, maybe will add them later.
 
#2 ·
Nice job NS!

So a lot of the hardware sits behind passenger lights and you routed the AN cooler lines through passenger side to front of AC condenser?

I’ve got a factory Aux radiator sitting there, am guessing being cooler climate UK TTS don’t have these?
 
#3 · (Edited)
Mine didn't have any extra coolers. Yes the space is tight, but I only had to cut a bit of the rubber air dam which goes vertically across the A/C radiator, to route the lines.
I forgot to mention the oil flow order: DSG sump (bottom) -> filter -> pump -> pressure sensor -> NRV -> radiator -> oil sump (top).

Pressure display:
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Control panel for pump, wmi, IC spray:
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