Step 11 - Installing the Intercooler Pipes

 

The Intercooler pipes are made from 304 stainless steel with a beautiful brushed finish. The two Intercooler pipes are distinctly different. The supercharger side pipe has more bends than the intake side pipe as shown in the photo to the right. There are four silicone hoses and clamps. The hump hose has the bulge in it to allow more flexing from the torque of the engine. The hump hoses use the smaller clamps for mounting and attaching to the Intercooler. The other two transitional silicone hoses mount on the engine side.  Soapy water simplifies the installation of the silicone hoses when sliding them onto the pipes, the dummy throttle body and supercharger outlet. To protect the silicone hoses we specify only liner-type clamps that won't tear the silicone surfaces and weaken the integrity of the silicone hoses.

Hardware Package A-2 and F

11-A Installing Intake Side Pipes

To make fitting of the silicone hoses to the parts easier, spray a little soap 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 of the two hose clamps supplied in Package F, 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. Place another clamp onto the top of the silicone hose.
     
  • Install the intake pipe into the lower connector hose. Take the 2 3/4" to 2 1/2" transition hose and slide it on to the Intercooler pipe at the top as shown in Photo 11-C.
     
  • Place two larger clamps onto the pipe with the tightening screws toward the fenders, as shown in Photo 11-D. Holding the assembly, rotate the intercooler pipe toward the dummy throttle body and line it up as shown.
     
  • Spray a little soapy water onto the hose connection and flange of the dummy throttle body, as shown in Photo 11-D. Then slide the hose connector over the flange on the dummy throttle body. This requires some tough pushing to get over the excessively large lip on the dummy throttle body. If you have some spare time, remove the dummy throttle body and with a grinder remove most of the lip to make it more "user-friendly."
     
  • Lightly secure all hose clamps into position, but don't tighten until both Intercooler pipes are installed as you will need to align the Intercooler pipes with the radiator shield.

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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
 
Photo 11-D: Use soapy water here Photo 11-E: Slide connector over DTB and secure clamps
 

11-2 Installing Supercharger Side Intercooler Pipes.

  • 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 hoses to the Intercooler using the smaller of the two pipe clamps supplied in Package F as shown in Photo 11-F. 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 down. Place another clamp onto the top of the silicone hose.
     
  • Install the supercharger pipe into the lower connector and have the end pointing inwards. Take a silicone hose and slide it on to the I/C pipe at the top end. Spraying a little soapy water can help aid the sliding.
     
  • Place two clamps onto the pipe as shown in Photo 11-G with the tightening screws toward the fender. Holding the assembly rotate the I/C pipe toward the Supercharger and line it up as shown in Photo 11-H
     
  • Spray a little soapy water onto the hose connection and flange of the Supercharger as shown in Photo 11-D. Then slide the hose connector over the flange on the Supercharge. This side is a little easier than the dummy throttle body, but does requires some pushing to get it on.
     
  • Lightly secure all the hose clamps into position, but don't tighten down until both Intercooler pipes are installed as you will need to align the I/C pipes with the radiator shield.

 

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Photo 11-F: Lower silicone connector supercharger side Photo 11-G: Rotate Intercooler pipe into position Photo 11-H: Align pipe. Use soapy water on connectors to help slide connector into place.
   
Photo 11-J: Tighten clamps, but you must be able to move them for shield fitting (see below).    

 

11.3 Installing the radiator shield temporarily will aid in aligning the Intercooler pipes before tightening.

  • 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-L. 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-M.
     
  • 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 as shown in Photo 11-N.

 

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

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