trinydex
04-12-2007, 08:23 PM
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.
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),
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2001.jpg
but by changing it out for a bigger one (figure B),
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2002.jpg
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)
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2003.jpg
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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2004.jpg
* 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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2005.jpg
* 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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2006.jpg
* 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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2007.jpg Once they're removed, the bar will pull right off.
* Now it's time to remove the factory intercooler. Remove the bolt that secures the hard pipe on both the passenger side (figure H)
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2008.jpg and the driver's side.
* The hose clamp can then be loosened from the intercooler (figure I)
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2009.jpg
on both sides and the passenger-side coupling removed.
* 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)
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2010.jpg
to release it from the car (figure K).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2011.jpg
Intercooler Installation (2nd Link)
* Use a panel removal tool to remove the two shrouds on either side of the radiator (figure A).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2012.jpg
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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2013.jpg
* 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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2014.jpg
* Align the passenger side coupler and Install the hard pipe retaining bolt behind the radiator support (figure D).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2015.jpg
* Attach the passenger side bracket over the bracket for the hard pipe, and then tighten the top intercooler mounting nut (figure E).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2016.jpg
* To finish up, slide the couplers into place and tighten the hose clamps securely (figure F).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2017.jpg
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.
Reassembling the Bumper
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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2018.jpg
When the bar is tight, grab the bumper cover and reattach the intercooler sprayer line.
* Slide the bumper cover into place (figure H).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2019.jpg
* Attach the two grill bolts first, then add the driver's side screw to hold it securely (figure I).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2020.jpg
* 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, andInstall the two clips and the bolt on each side (figure J).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2021.jpg
* 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.
*from: http://www.diynetwork.com/diy/cda/article_print/0,1983,DIY_13686_4212986_ARTICLE-DETAIL-PRINT,00.html & http://www.diynetwork.com/diy/cda/article_print/0,1983,DIY_13686_4213000_ARTICLE-DETAIL-PRINT,00.html*
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.
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),
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2001.jpg
but by changing it out for a bigger one (figure B),
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2002.jpg
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)
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2003.jpg
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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2004.jpg
* 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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2005.jpg
* 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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2006.jpg
* 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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2007.jpg Once they're removed, the bar will pull right off.
* Now it's time to remove the factory intercooler. Remove the bolt that secures the hard pipe on both the passenger side (figure H)
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2008.jpg and the driver's side.
* The hose clamp can then be loosened from the intercooler (figure I)
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2009.jpg
on both sides and the passenger-side coupling removed.
* 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)
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2010.jpg
to release it from the car (figure K).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2011.jpg
Intercooler Installation (2nd Link)
* Use a panel removal tool to remove the two shrouds on either side of the radiator (figure A).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2012.jpg
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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2013.jpg
* 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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2014.jpg
* Align the passenger side coupler and Install the hard pipe retaining bolt behind the radiator support (figure D).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2015.jpg
* Attach the passenger side bracket over the bracket for the hard pipe, and then tighten the top intercooler mounting nut (figure E).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2016.jpg
* To finish up, slide the couplers into place and tighten the hose clamps securely (figure F).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2017.jpg
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.
Reassembling the Bumper
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).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2018.jpg
When the bar is tight, grab the bumper cover and reattach the intercooler sprayer line.
* Slide the bumper cover into place (figure H).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2019.jpg
* Attach the two grill bolts first, then add the driver's side screw to hold it securely (figure I).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2020.jpg
* 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, andInstall the two clips and the bolt on each side (figure J).
http://www.socalevo.net/gallery/albums/userpics/10991/Install%20Intercooler%2021.jpg
* 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.
*from: http://www.diynetwork.com/diy/cda/article_print/0,1983,DIY_13686_4212986_ARTICLE-DETAIL-PRINT,00.html & http://www.diynetwork.com/diy/cda/article_print/0,1983,DIY_13686_4213000_ARTICLE-DETAIL-PRINT,00.html*