DIY Network

Intercooler Upgrade: Introduction and Prep Work From "Tricked Out" episode DTRK-206

	The project car: 2003 Mitsubishi Lancer Evolution. In this Tricked Out upgrade, the EVO gets a high-performance intercooler to replace the factory component. Click below to watch a video on intercooler basics.
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In a turbocharged engine, an intercooler system cools intake air temperature to increase horsepower and decrease emissions. In this episode, host Andrew Totolos replaces a stock intercooler with an aftermarket one that gives more oomph! to a Mitsubishi Lancer Evo. Later, the pipes that route air through the engine are upgraded with silicon soft-pipes to provide quicker response. In this first segment, Andrew begins the intake upgrade as he removes the factory-installed intercooler.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Intercooler kit
Boost pipe
Intake pipe
Panel clips
Panel removal tool
Pliers
Socket extension

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 3 on a 5-point intermediate-level scale. No special tools are required. Just a lot of patience removing some factory parts and the front bumper.

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The Project Car: Mitsubishi Lancer Evolution

This 2003 Lancer EVO-8 belongs to Josh Powell. It sports an electric-blue paint job and lightweight wheels. The Mitsubishi Evolution is one of the hottest factory sports-compacts available.

Developed through years of world rally championship racing, the 4-G63 Mitsu engine produces 270 horsepower before any mods. But on this one, the owner has installed a 3-inch exhaust and down-pipe to let the factory turbo breathe freely. A vented blow-off valve keeps the turbo spinning between gears, and gives that signature turbo-spool sound.

	Figure A
	Figure B
	Figure C
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Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Intercooler Basics

In order to make power, engines need fuel, oxygen, and spark. If you can increase the amount of oxygen in the combustion chamber, the car will dump more fuel in and boom, you get more power. Turbochargers force more air into the engine for a bigger bang, but they also heat the intake air--and hot intake-air robs power. Your first line of defense is an intercooler. It works like your car's radiator, but instead of coolant, it brings charged air from your turbo back to tolerable temperatures. Our Evo has a factory-installed intercooler already (figure A), but by changing it out for a bigger one (figure B), we'll get better air flow and cooling, which means denser, more oxygen-packed air in the cylinders and a faster ride.

The new larger intake pipes (figure C) increase the effect by letting more air pass by virtue of larger diameter tube with fewer bends and smoother lining. All of these parts bolt right on, so the installation is pretty easy.

Removing the Bumper and Factory Intercooler

• The first step is to remove the factory plastic so you can get to the parts. Modern compact cars are incased in plastic, even underneath the engine. The EVO has a two-piece skid panel that will come right out once you remove all the panel clips with a panel removal tool (figure D).

• Inside the fender well, there are two panel clips and a bolt that attach to the front bumper cover. Once they're out, pull the bumper cover down at the fender well to release the fender mounting clips.

• Under the hood, remove the two panel clips and two screws that secure the bumper cover to the radiator support. Remove those (figure E).

  Figure D

  Figure E

  
  

• Remove one more screw on the driver's side, along with the two bolts accessed through the front grill, and then you'll be able to pull the bumper cover forward (figure F).

• The EVO-8 has a factory intercooler sprayer that should be disconnected to completely remove the bumper cover from the car.

• Underneath the bumper cover on the EVO is the factory bumper, also known as the crash bar. If you're planning on upgrading to a front-mount intercooler or moving up to a larger one from your factory front mount, be sure to get one that lets you keep this impact protection. There are four bolts that hold the crash bar in place. You'll need a socket and an extension to reach them (figure G). Once they're removed, the bar will pull right off.

  Figure F

  Figure G

  
  

• Now it's time to remove the factory intercooler. Remove the bolt that secures the hard pipe on both the passenger side (figure H) and the driver's side.

• The hose clamp can then be loosened from the intercooler (figure I) on both sides and the passenger-side coupling removed.

  Figure H

  Figure I

  
  

  	Figure J
  	Figure K

• There's a bolt to remove on either side of the intercooler and one final securing nut at the top that will need to be removed.

• After all the bolts are removed, carefully pull the intercooler up, forward and off of the driver's side coupling (figure J) to release it from the car (figure K).

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

TEIN USA, Inc.
Website: www.tein.com

Focus Sport
Anaheim, CA
www.focussport.com