Step 11 - Installing the Intercooler Pipes

The Intercooler pipes are made from 304 stainless steel with a beautiful brushed finish. For the turbo cars there are two distinctly different intercooler pipe setups depending on your aftermarket turbo setup. To protect the silicone hoses we specify only liner-type clamps that won't tear the silicone surfaces and weaken their integrity. Please contact TDR if you need a replacement. Standard hose clamps will destroy the silicone hoses.

11-1 Installing the FM System Intake Side Intercooler Pipes

The FM turbo Intercooler kit comes complete with the turbo outlet pipe, turbo inlet pipe and the intake pipe. The FM air filter and air box are retained.

To make fitting of the silicone hoses to the parts easier, spray a little soapy water onto the hose connection before installing. The soapy water also acts as a sealant when it dries.

  • To simplify installation and removal of the silicone hoses on the Intercooler, mount the clamps so that the tightening screw is on the front side, as shown in Photo 11-A. This will give you more clearance with a nut driver (recommended for more torque) or screwdriver.
     
  • Install the hump hoses onto the Intercooler using the smaller size hose clamps as shown in Photo 11-A. Slide the hose down so that the bottom of the hump is at the top of the Intercooler pipe.  Ideally you want the top Intercooler pipe to mount just above the hump to allow flexing in between. Tighten the bottom clamp secure. Place another clamp onto the top of the silicone hose. Photo 11-A also shows placement of the factory horn mounted to the top of the intercooler.
     
  • Install the intake pipe into the lower connector hose. Take the 2 1/2" silicone hose and slide it on to the Intercooler pipe at the top as shown in Photo 11-B.
     
  • Place two larger clamps onto the pipe with the tightening screws toward the inside, as shown in Photo 11-B. Holding the assembly, rotate the intercooler pipe toward the throttle body and line up as shown.
     
  • Spray a little soapy water onto the hose connection and flange of the throttle body. Slide the hose connector over the flange of the throttle body.
  • Lightly tighten all of the hose clamps, but don't securely tighten until both Intercooler pipes are installed as you will need to align the Intercooler pipes with the radiator shield.

CAUTION: You need to keep about a 1/4" to 3/8" space between the pipes and the component that it attaches to for proper flexing. Damage to the Intercooler could occur from engine torque.

Click on thumbnail image to see larger image in a new window

Photo 11-A: Lower silicone connector intake side Photo 11-B: Insert intake pipe into silicone connector Photo 11-C: Rotate I/C pipe into position
 

11-2 Installing FM System Turbo Side Intercooler Pipes.

  • Install a 2 1/2" silicone hose to the turbo inlet along with the turbo inlet pipe. Secure the clamp on the turbo side as shown in Photo 11-D.
  • Install the 3/8" barb fitting in the turbo inlet pipe for the valve cover vent hose as shown in Photo 11-E.
  • Install the MFS unit using the 2 1/2" to 2 3/4" transition hose and secure as shown in Photo 11-D
  • Using the rubber hose elbow as shown in Photo 11-F, determine the length needed to hold the BOV to the turbo outlet pipe, usually this is about 1 3/4" long. Cut the hose on the short length of the elbow as shown in Photo 11-G. Be sure to fit the unit to the pipes before cutting.
  • Install the hump hose to the Intercooler using the smaller pipe clamps facing toward the front as shown in Photo 11-H. Slide the hose down to were the bottom of the hump is at the top of the Intercooler pipe.  Ideally you want the top Intercooler pipe to mount just above the hump to allow flexing in between. Tighten the bottom clamp securely. Place another clamp onto the top of the silicone hose.
  • Install the 2" silicone hose to the turbo outlet pipe as shown in Photo 11-I. Attach two clamps while securing the bottom clamp only.
  • Install the turbo outlet pipe into the lower connector and into the turbo outlet. Spraying a little soapy water can help aid the alignment. Tighten the clamps, but not securely until the final alignment as shown in Photo 11-I
     
  • Install the BOV hose into the turbo outlet pipe and tighten the clamps, but not securely tighten until the final alignment as shown in Photo 11-J.
     
  • Attach a 1/8" vacuum hose to the BOV and to either the turbo outlet fitting or the turbo outlet pipe. A 1/8" brass barb fitting is supplied and if not used a plug is also supplied.

NOTE: After pipe alignment check all fittings to make sure they are secure.

Click on thumbnail image to see larger image in a new window
Photo 11-D: Turbo intake pipe and connector hoses Photo 11-E: Valve cover vent tube in intake pipe Photo 11-F: Customer's BOV installed in black hose
Photo 11-G: Cut the BOV hose as required on the straight, short end Photo 11-H: Install hump hose with clamps toward the front. Photo 11-I: Install turbo outlet hose with clamps on turbo
   
Photo 11-J: Install BOV to the turbo outlet pipe    

 

11.3 Installing the BRP System Intake Side Intercooler Pipes

The BRP turbo Intercooler kit comes with four pipes. The turbo outlet consist of two pipes separated by a silicone hump hose to add more flex. The non-intercooled version did not have a proper intake/filter setup. The TDR kit includes a new intake pipe setup with new air filter. Some of the early versions came with proper recirculating BOV, blow-off-valves which you will reuse. If your version did not have this setup, you will be required to purchase a recirculating BOV. TDR sells an inexpensive model for $49 or there are other models such as those from Turbo XS that are available.

To make fitting of the silicone hoses to the parts easier, spray a little soapy water onto the hose connection before installing. The soapy water also acts as a sealant when it dries.

  • To simplify installation and removal of the silicone hoses on the Intercooler, mount the clamps so that the tightening screw is on the front side, as shown in Photo 11-K. This will give you more clearance with a nut driver (recommended for more torque) or screwdriver.
     
  • Install the hump hoses onto the Intercooler using the smaller size hose clamps as shown in Photo 11-K. Slide the hose down so that the bottom of the hump is at the top of the Intercooler pipe.  Ideally you want the top Intercooler pipe to mount just above the hump to allow flexing in between. Tighten the bottom clamp securely. Place another clamp onto the top of the silicone hose. Photo 11-K also shows placement of the factory horn mounted to the top of the intercooler.
     
  • Install the intake pipe into the lower connector hose. Take the 2 1/2" silicone hose and slide it on to the Intercooler pipe at the top as shown in Photo 11-L.
     
  • Place two larger clamps onto the pipe with the tightening screws toward the inside, as shown in Photo 11-L. Holding the assembly, rotate the intercooler pipe toward the throttle body and line up as shown.
     
  • Spray a little soapy water onto the hose connection and flange of the throttle body. Slide the hose connector over the flange of the throttle body.
  • Lightly tighten all of the hose clamps, but don't securely tighten until both Intercooler pipes are installed as you will need to align the Intercooler pipes with the radiator shield.
  • Install the BOV to the intake pipe using about 1 3/4" of the 1" silicone hose supplied. Clamp the hose to the intake pipe and BOV as shown in Photo 11-M.
  • Measure and cut the 1" silicone hose to fit between the BOV and the turbo intake pipe.
  • Attach the 1/8" vacuum hose to the BOV and intake manifold as shown in Photo 11-M.

CAUTION: You need to keep about a 1/4" to 3/8" space between the pipes and the component that it attaches to for proper flexing. Damage to the Intercooler could occur from engine torque.

Click on thumbnail image to see larger image in a new window
Photo 11-K: Install hump hose on to intercooler with clamps Photo 11-L: Insert intake pipe into silicone connector Photo 11-M: Install BOV into intake pipe

11-4 Installing BRP System Turbo Side Intercooler Pipes.

  • Install the 2 1/2" to 2 1/4" transition hose to the turbo inlet. Secure the clamp on the turbo side as shown in Photo 11-N.
  • Install the 3/8" brass barb fitting for the valve cover vent hose on to the turbo intake pipe. Attach a 3/8" hose to the fittings as shown in Photo 11-O and attach to the valve cover vent fitting.
  • Clean up the wiring area where the air filter will be located. You can clip the holders on the base for the wiring harness and the hood release cable and bring above the headlight assemble. Tie-Wrap the relays and harness together. You can push the relays under the fender area behind the headlight assembly as shown in Photo 11-P.
  • Install the 90 deg. silicone elbow to the stainless steel elbow with large clamps as shown in Photo 11-Q.
  • Install the MFS to the hose and place so the terminals face upward as shown in Photo 11-Q. Clamp lightly until all the components are installed.
  • Install the air filter with the fitting for the temperature sensor facing upwards as shown in Photo 11-R. Install the air temperature and MFS wiring connector. The air filter has a stainless steel seam that is exposed as shown in Photo 11-R, you can paint this black with a Sharpie or paint to hide the seam.
  • To simplify installation and removal of the silicone hoses on the Intercooler, mount the clamps so that the tightening screw are on the front side. This will give you more clearance with a nut driver (recommended for more torque) or screw driver.
  • Install the hump hose on the intercooler to were the bottom of the hump is at the top of the Intercooler pipe.  Ideally you want the top Intercooler pipe to mount just above the hump to allow flexing in between. Tighten the bottom clamp securely. Place another clamp onto the top of the silicone hose.
  • Install the turbo outlet flanged pipe using the 6 x 25 mm supplied hardware. Use existing flange gasket or silicone sealer.

NOTE: The turbo may require clocking or twisting to align the pipes. Use a rubber mallet or other means if you are not able to simply turn the turbo housing with force.

  • Install the lower turbo outlet pipe into the intercooler hose, make sure there is a clamp on the hose.
  • Install the 2" hump hose on the lower pipe with hose fittings. Test for alignment and space between the two pipes. Ideally you want about a 1/4" to 3/8" clearance between the two pipes. Slide the hose over the turbo outlet pipe and secure as shown in Photo 11-U.

NOTE: Pipe alignment should be close, but does not have to be exact, the hump hose can help in some misalignment.

Click on thumbnail image to see larger image in a new window
Photo 11-N: Install transition hose into the turbo inlet Photo 11-O: Install valve cover vent hose to turbo inlet pipe Photo 11-P: Clean up wiring area for more room in the filter area
Photo 11-Q: Install 90 deg. hose and MFS with terminal up Photo 11-R: Adjust hose fittings and connect air temp into filter Photo 11-S:Install hump hose on to intercooler with clamps
 
Photo 11-T: Install flange fitted pipe to turbo outlet Photo 11-U: Install lower pipe into intercooler and into hump hose connection  

11.5 Installing the radiator shield temporarily for aligning the Intercooler pipes before securely tightening the clamps.

  • Take the aluminum radiator shield and place it on the rubber radiator supports and the studs on the sub frame, as shown in Photo 11-V. Check the fit between the shield and the Intercooler pipes to make sure you have good clearance and are not making contact with the shield as shown in Photo 11-V.
     
  • Securely tighten the hose clamps on the engine side to maintain alignment of the Intercooler pipes. Use a nut driver for more torque.
     
  • Remove the aluminum radiator shield and securely tighten all the Intercooler hose clamps.
     
  • Finally attach the aluminum radiator shield using the two supplied 13mm Acorn nuts from Package A-2.
Click on thumbnail image to see larger image in a new window

Photo 11-V: Check pipe position. Here it is too far to the left. Photo 11-W: Pipe position properly. Repeat for other side and then tighten down all clamps (upper and then lower). Photo 11-X: Finished installation

Next - Step 12: Installing The Lower radiator Panels

Step 1: Removal Of Factory Parts Step 8: Installing The Power Steering Cooler
Step 2: Installing The Radiator Brackets Step 9: Installing The Radiator
Step 3: Modifying The Radiator Cross Member Step 10: Installing The A/C Evaporator Coil To The Radiator
Step 4: Modifying The Evaporator Canister Step 11: Installing The Intercooler Pipes
Step 5: Installing The I/C Mounting Support Panels Step 12: Installing The Lower Radiator Panels
Step 6: Installing The Radiator Shroud Panels Step 13: The Final Adjustments
Step 7: Installing The Intercooler Main Page

©2004 Track Dog Racing™ All Rights Reserved