Post on 10-Apr-2018
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FMCZTINTMitsubishiColtCZTfront
mountingintercoolerinstallation
Toolsneeded:
Drillwith8mmHSSdrillbit,hacksaw,dremel/stanleyknife
3/8driveratchetwithextensionand10mm,13mmsockets
TorxT25andT30bits
7mmhoseclipdriveror7mmsocket
6mm
allen
key
or
socket
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KITLIST
1xintercooler
1xhornbracket
2x50mmdiametersiliconjoiner
2x50mmdiameter90degreesiliconelbow
1x50mmdiameter90degreealuminiumelbow
1xcustomaluminiumpipewithturbooutletflangeononeend
1xcustomaluminiumpipewith45degree bendononeend
8x4560mmjubileeclips
6xM8pennywashers
2xM8x40allenheadbolts
2xM8x12allenheadbolts
2xM8nylocnuts
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1. Jackthefrontofthecarupintheairandsupportonaxlestands.DONOTworkunderthecarwithjustajacktakingtheweight.Openthebonnet.Workinginthe
wheelarches,removethe8mmselftappingscrewatthetopofthearchandthe
poppertypefixinghalfwaydownthearch,byleveringundereachsideofthe
popperuntil
it
can
be
withdrawn.
Do
this
on
both
wheel
arches.
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2. Removethefrontnumberplate(ourswasstuckonuseheatfromahairdryertosoftentheglueandbendtheplateoffslowly)andpulloutthefixinginthemiddleof
thebumper.
3. Workingunderthefrontofthecar,removetheengineundertraybyremovingthe15(yes
15)
popper
style
fixings,
5down
each
side.
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.andfiveunderthefront.Theundertrayshouldnowpullfreetowardsthebackof
thecar.
4. Stillunderthecar,removetheedgesofthebumperformthewheelarchliners,twooneachsideofthecar.
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5. Underthebonnet,undothefourT30screwsholdingthetopofthebumpertotheslampanel.TAKECAREtoremovethecorrectfourscrewsasindicated.LEAVETHE
TWOMIDDLESCREWSLOOSELYSCREWEDINitwillstopthebumperfromfalling
offinthenextstep.
6. Workingonthewheelarch,placeyourhandunderthearchlinerbehindthebumperandpullsharplyoutwardsthebumperisheldfirmlyinplacebythreeplasticclips.
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Plasticclipsforreference:
7. Repeatonbothside,thenremovethetwoT30screwsyoustillhadlooselyscrewedin.Supporttheweightofthebumper,andpullitforwardslightlytoreachdownand
undothewiringtothefoglights(simplysqueezetheconnectortoremoveit),then
removethe
bumper
and
place
somewhere
safe.
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8. RemovethepassengersideheadlightbyundoingthethreeT25retainingscrews,thenreleasethewiringfromtheundersidebysqueezingontheplastictabsbefore
removingitfromthecar.
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9. Workingbackunderthefrontofthecar,locatetheturbooutletpipe,andusinga10mmsocket(ideallyasixsidedsocket)undobothofthestarshapedbolts.Retain
thegasketforfutureuse.
10.Undothehoseclampholdingtheintercoolerinletpipefromthebottomofthestockintercoolerandremovethewholepipefromthecarwiththeturbooutletattached.
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11.Undothethree13mmretainingboltsholdingtheintercoolertothechassis.Oneofthemisuparoundthebackoftheintercoolerandwillrequirealongextensionpiece
onyourratchet.Undotheintercoolertophose(atbothends),andremovethe
intercoolerfromthecar.Removethetoprubberintercoolerhosefromthecaralso.
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12.Younowneedtomounttheintercoolerontothebumperbar,butyouneedtoremovethebumperbarfirst.Unclipthebonnetreleasecable,removethesingle
10mmboltinthecentreandthetwo13mmnutsoneachendofthebarandremove
itfromthecar.
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13.Offeruptheintercoolertothebumperbar.Themountingholesonthebracketsare295mmapart.Takethe10mmboltonthetopofthebarasthemiddle,eachofyour
holesneedstobe147.5mmtotheleftandrightofthecentreofthathole.Marktwo
linesonthebartorepresentthis,thenofferthecoreup.Pushthecorehardagainst
theback
of
the
bar,
with
the
brackets
over
the
lines
you
already
drew,
and
mark
the
middleoftheholeforeachbracket.Thiswillbewhereyoudrillyourholes,andifall
hasgonetoplan,thecoreshouldbeinthemiddleofthebar.
14.LooselymountthecoretothebumperusingtheM8x12bolts.Putapennywasherundereachboltthenpushthroughtheintercoolerbracket,thenonepennywasher
betweenthebracketandthetopofthebumperbar.SecurewiththeM8nutinthe
cavityaccessedfromthefrontofthebar.
147.5mm
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15.Remountthebumperbartothecar,withtheintercoolerstilllooselyattached.Theintercoolerneedstorestontheledgeatthebottomoftheradiatorcowling,oncein
place,tightentheintercoolermountingbolts.Iftheintercoolerneedsspacing
upwards,wehaveprovidedtwosparepennywasherstoplacebetweenthetopof
thebumper
bar
and
the
underside
of
the
intercooler
brackets.
16.Mountthetwo50mmsiliconcouplerstotheendsoftheintercooler,andthenlookattheintercoolerfromthesideandmarkuptheareasoftheplastictrimaroundthe
cowlingthatneedstoberemoved,thenremovethetrimbypullingitawayandcut
outtheplasticwithadremelorsimilar(Stanleybladeworkstoo).
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17.Withthetrimremoved,youalsoneedtocutoffthelocatinglugfromtheradiatorcowlingsoitscompletelyflush,andundotheT25screwholdingthehornbracket.
18.Undothe13mmnutfromthebackofthehornunit,andremovethebracket.ReplacewiththeForgehornbracketsupplied,andremountthehornwiththe
bracketangled
towards
the
back
of
the
car.
Locatin lu
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19.Usingahacksaw,cutthebottomleft(fromthefrontofthecar)rearedgeoftheradiatorcowlapprox60mmlongand10mmdeepata45degreeangleuptothe
reinforcingintheplastic.
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20.NowtoinstallthepipeworkfindthehardpipewiththeCNCdturboflangeonit,andthegasketyouremovedearlierfromthestockturbooutlet.UsingtwoM8x20
allenheadboltsandasuitableallenkey,bolttheturbooutletpipeintopositionwith
theoutletpointingtotheleft(fromthefrontofthecar).
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21.Jointhe90degreealuminiumelbowintooneofthe90degreesiliconelbowstoforma180degreebend.Placetwohoseclipslooselyonthe90degreesiliconbend,and
twohoseclipslooselyboth50mmcouplersalreadyontheintercoolerfromstep16.
Observetheorientationoftheclipsasshownbelow,whichwillmakeiteasierto
tightenthem.
Join
the
turbo
outlet
hose
to
the
intercooler.
You
may
need
to
adjust
thehoses,andmightfinditeasiertolubricatethesiliconhoseswithasiliconspray
(dashboardcleaner/backtoblackworkwell).
Whenthepipeworkisinplaceandyouhaveatleast20mmofaluminiumpipework
ineachendofthesiliconhose,tightenalltheclips.Youwillfinditeasiesttotighten
thesilicontoturbooutlethosefromtheback.
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22.Ontheothersideofthecar,placetheremaining90degreesiliconhoseontheendofthestockpipeworkundertheheadlight,togetherwithtwoloosehoseclips.
Inserttheremaininghardpipeintothecouplerontheintercooler,andthenpushit
upinto
the
90
degree
bend
just
added.
When
it
fits
well,
tighten
all
the
hose
clips.
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23.Yourinstallshouldnowbecomplete,andlookinglikethis:
Followsteps7to1toreplacethestockbumper,andenjoyyournewintercooler.
ENGINEEREDFOR
PERFORMANCE
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