Boy-Dirt-Car
Member
So ZZP sells their Intercooler separately for a reasonable price so I bought one. Unit is very well made but there was a problem with how far down (Up?) the mounting posts were as it wouldn't fit underneath the A/C Condenser. Modification required, read on!
Here's the stock and ZZP Intercoolers side-by-Side for comparison. I did up an RS Stencil and painted it, Cool eh?
Next take off the Bumper Cover, Crash Bar and Diverter thingy.
Don't let the instructions (or the Service Manual) fool you, you need to completely remove the wire retainer from the hose-to-stock intercooler connection, what a pain in the ***.
ZZP Intercooler in-place, but not before some modification.
Here you can see that I needed to remove about 3/8" from the bottom of the mounting posts to get it to fit under the A/C Condenser.
There was no way to use the original hose-to-intercooler connector so I cut them off and left as much hose as I could as I wasn't sure how much of the hoses I was gonna need. Used some Intercooler hose clamps from Weaver Auto Parts to securely fasten the hose to the new Intercooler.
I pushed to hose onto the intercooler nipples as far as it looked like they should go, using their natural shape to gauge it.
I wanted to utilize the diverter thingy somehow so I tied it to the intercooler with a couple of monster zip ties. Some modding/trimming required. The only problem with this solution, as I found out, was that I now couldn't mount the crash bar, Oh Well!
Here's the stock and ZZP Intercoolers side-by-Side for comparison. I did up an RS Stencil and painted it, Cool eh?
Next take off the Bumper Cover, Crash Bar and Diverter thingy.
Don't let the instructions (or the Service Manual) fool you, you need to completely remove the wire retainer from the hose-to-stock intercooler connection, what a pain in the ***.
ZZP Intercooler in-place, but not before some modification.
Here you can see that I needed to remove about 3/8" from the bottom of the mounting posts to get it to fit under the A/C Condenser.
There was no way to use the original hose-to-intercooler connector so I cut them off and left as much hose as I could as I wasn't sure how much of the hoses I was gonna need. Used some Intercooler hose clamps from Weaver Auto Parts to securely fasten the hose to the new Intercooler.
I pushed to hose onto the intercooler nipples as far as it looked like they should go, using their natural shape to gauge it.
I wanted to utilize the diverter thingy somehow so I tied it to the intercooler with a couple of monster zip ties. Some modding/trimming required. The only problem with this solution, as I found out, was that I now couldn't mount the crash bar, Oh Well!
