DIY Network

Intercooler Upgrade: Installing the New Intercooler From "Tricked Out" episode DTRK-206

	This Mitsubishi Lancer Evo gets an upgraded intercooler to enhance turbo efficiency.
	The larger intercooler has more surface area for better heat exchange.

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In this project, host Andrew Totolos replaces a stock intercooler with an aftermarket one provides more power to a Mitsubishi Lancer Evolution. Now that the factory intercooler has been removed, it's time to install the new intake system. Andrew begins by installing the new 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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Andrew compares the factory intercooler (rear) to the high-performance replacement (front).

The High-Performance Intercooler

Compared to the factory intercooler we removed, the larger aftermarket replacement we're installing has more cooling surface which means that the intake air will be cooled more efficiently. Also, the larger mass of the new unit will dissipate heat better. While the old tank was a comfortable fit, the new one will stretch the entire length of the front grill for maximum cooling. The factory intercooler is a wing design in which air passes through small, flattened tubes. Our new intercooler is a bar-and-plate design, and the rows are much bigger. The same amount of air passing through the larger channels will move more slowly and undergo a greater cooling effect. The replacement is also stronger than the wing design, which is important since a front-mount intercooler is a prime target for road debris.

Intercooler Installation

• Use a panel removal tool to remove the two shrouds on either side of the radiator (figure A). Keep them with the old intercooler in case you ever want to put it back.

• Next, slide the old couplers off and replace them with the new silicone couplers making sure to leave clearance for the intercooler. Leave two hose clamps loose on each side (figure B).

  Figure A

  Figure B

  
  

  
  

• Hang the new intercooler on the center stud and loosely attach the center nut to hold the intercooler in place.

• Use the new bolt and spacer to attach the driver's side bracket (figure C).

• Align the passenger side coupler and install the hard pipe retaining bolt behind the radiator support (figure D).

  Figure C

  Figure D

  
  

  
  

• Attach the passenger side bracket over the bracket for the hard pipe, and then tighten the top intercooler mounting nut (figure E).

• To finish up, slide the couplers into place and tighten the hose clamps securely (figure F).

  Important: These connections will be under a lot of pressure when the engine is running, and a leak here would cause significant loss of performance.

  Figure E

  Figure F

  
  

  
  

After you get the new intercooler tightened down you can go ahead and replace the crash bar, the bumper cover, and the trays underneath.

• To begin, hook the crash bar to the frame with the tabs on top and then reinstall the four securing bolts (figure G). When the bar is tight, grab the bumper cover and reattach the intercooler sprayer line.

• Slide the bumper cover into place (figure H).

  Figure G

  Figure H

  
  

  	Figure I
  	Figure J

  
  

• Attach the two grill bolts first, then add the driver's side screw to hold it securely (figure I).

• Secure the two top bolts and then pop the panel clips in the top.

• Pop the bumper into the hidden finder clips near the tire wells, and install the two clips and the bolt on each side (figure J).

• Finish up by re-installing the skid plate underneath. Be sure to replace any panel clips that were broken when you took off the cover.

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

Focus Sport
Anaheim, CA
www.focussport.com