| View Other HOWTOs |
| Do it yourself intercooler (This is the alternative to buying a Paxton Air to Air or Vortec's aftercooler at a 1/3 of the cost. ) |
| Step 1: Parts List |
| Step 2: Tool List |
| Step 3: Step 3 Installation |
Step 3 Installation |
| (1) First you will need to pull the two retaining clips out of two front headlights and disconnect head lights and fog lights. Remove headlights and store safely. Remove Clips holding bumper cover on located at the top of bumper. At this time you should jack the front up and put car on stands. Next you will remove the final four bolts two on each side about where the bumper meets the fender on the inside. Once those bolts are revoved the bumber cover will come off. (2) You will need to bend the Power steering cooling tube out of your way to make room for intercooler. (*Weld beeds on lips of pipe for boost higher than 6 psi is recomended. If you are not welding fit all pieces then remove and have a shop do it for you.) (3) Measure the location of studs on intercooler and mark front frame so the intercooler will be centered in front of car. The top of the intercooleler can be supported using allthread and L brackets although it may not be necessarry. I suggest using a Tap tool and bolt or bolt and nut to mount the L brackets. [ click to enlarge ] (4) At this time start cutting the silicone hoses 3" and fit on intercooler. Measure 90* and cut so pipe clears frame on either side and install 3" silicone sleave on each 90*. (5) You will have to remove the radiator overflow rear tank support to run tubing to blower.(we will reinstall later) (6) Now install another 90* on driver side and install silicone sleave on 90*. (see pic.) [ click to enlarge ] (7) At this time you will need to cut the 90* on short end to create a 45* that will mount to a blower. [ click to enlarge ] (8) You will need to loosen the allen key bolts on the blower and turn to aim to bottom of car and connect to intercooler piping. [ click to enlarge ] [ click to enlarge ] (9) Reinstall the radiator overflow rear tank support. You may need to einstall new tap screws to reconnect.(See pic) [ click to enlarge ] (10) You will need to notch the fender well to allow piping to run out of the intercooler and up to the intake. I found the dremil tool to work very well due to its size. be sure to to hold it steady using both hands because it will try to jump if your not careful. *(DO NOT CUT THE U SUPPORT CHANNEL AREA THAT RUNS CLOSEST TO THE ENGINE.) After cutting it is a good idea to tap the edges downward with a nylon/rubber hammer and paint cut areas to prevent rust. You can put door edgeing around the cut area if you would like. [ click to enlarge ] (11) Cut one of your 90* pipes on the short side to allow pipe to rise on a 45* connect this pipe to the 90* installed on the pasenger side of the intercooler. It will go through the cut area. [ click to enlarge ] [ click to enlarge ] (12) Install silicone hose with 3" pipe with BOV adapter on it. then install another silicone peice on adapter pipe. [ click to enlarge ] [ click to enlarge ] (13) Cut one more 90* on short side and connect to throttlebody. with silcone hose. [ click to enlarge ] Pictures show worm drive clamps but they were replaced with t bolt clamps. The worm drive clamps could not hold the boost and blew apart. |
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