The TDR intercooler instructions assume that the factory power steering and air conditioner are in place and that the factory shipping tie-down hooks that are located in the radiator area are already removed. If the tie downs have not been removed there are three 17mm bolts holding each of them on.

Drive your car onto a level surface, put the car in gear, apply the parking brake and block off the rear wheels. Jack up the front of the car and secure with jack stands. Remove both front wheels.

1.1 Belly Pan Removal

Remove the factory belly pan. It will be reused. The hardware uses 10mm bolts and Phillips screws.

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Photo 1-A: Remove belly pan	Photo 1-B: Lower radiator hose	Photo 1-C: Upper radiator hose

1.2 Radiator Removal

If the radiator fluid is still good, drain it into a container for reuse. (Caution: The radiator fluid could be hot and burn your skin. Radiator fluid is toxic so keep the fluid away from pets and children.)

• From below the car: Remove the radiator drain plug.  After the radiator fluid begins to drain, remove the radiator cap to let the fluid drain more quickly.  Disconnect the lower radiator hose and have a catch can handy because radiator fluid will be leaking out from the hoses as shown in Photo 1-B. Using a 10mm socket, remove the bolt that holds the bracket for the A/C hoses as shown in Photo1-D.
   
• From above the car: Remove existing crossover tube if it is still in place. Push small rags into the supercharger and throttle body openings to make sure metal filings don't get into the engine. Remember to remove the rags before installing the intercooler tubes!
   
• Disconnect the upper radiator hose from both the radiator and thermostat housing as shown in Photo 1-C. This will be trimmed in a later step before reattaching. Disconnect the radiator overflow hose.

• Remove the two 10mm nuts that hold the radiator brackets in place as shown in Photo 1-E.  

• Disconnect the two power connections for the radiator fans.
   
• Once everything is disconnected, lift the radiator out and place it in a safe location.

1.3 A/C Condenser Coil Removal

The A/C condenser is removed to modify the mounting brackets. If you don't have A/C pass on this step.

• Remove the four 10mm bolts from the A/C condenser's upper and lower locations, as shown in Photos 1-G through 1-I.

• Gently pull up on the condenser to remove it from the lower mounts, then push it towards the engine, being careful not to damage the unit. Use a bungee cord or similar strap to gently hold back the A/C condenser coil out of the way. 

• Remove the factory horn. You can reinstall it after the Intercooler is installed. An alternate location may be required.

1.4 Front Intake Area

Remove the plastic shroud in the mouth of the car and modify the frontal area.

• There are several plastic screw clips that hold the shroud in place. When all the screws, clips, nuts and bolts are removed, pull the shroud out through the bottom of the car. This will not be reused.
   
• Remove the plastic plugs under the bumper. If you are unable to remove the plastic fasteners using a screwdriver, use a hacksaw and cut between the bumper and the plastic support as shown in Photo 1-K. These will be replaced with new ones included with the kit.

• Cut straight across on the two metal tabs that are blocking the opening as shown in Photo 1-L. They serve no purpose anymore. A single-ended hacksaw works best with the minimal area to work with. Photo 1-K shows the brace after being modified. 

OPTIONAL

The 3 tabs on the bumper as shown in Photo 1-M that the cowling was attached to can be cut off for appearance. If reinstalling the cowling in the future the tabs do not affect the integrity of the mounting.

• Cut away the three plastic tabs that was holding the shroud in place as shown in Photo 1-M.

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Photo 1-J: Remove front radiator shroud panel	Photo 1-K: Remove plastic screw clips under the bumper	Photo 1-L: Cut off metal tabs
Photo 1-M: Remove shroud bumper tabs

1.5 Power Steering Cooler Removal

If you have power steering you will see the cooling pipe that needs to be removed. This will be modified later on. If you do not have power steering or a cooling tube, skip this step. .

• Remove the two 10mm bolts that hold the cooling tube in position as shown in Photo 1-N.
   
• Using pliers bend the tabs back on each brackets side as shown in Photo 1-O and remove.

• Place power steering tube off to the side until Step 8 where we will continue the modification.

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