Audi B8 Front Mount Intercooler

List of Parts Included

(1) Intercooler core with cast endtanks(1) Billet Aluminum Intercooler Brace(1) Billet Aluminum 2.00” to 2.50” turbo outlet adapter(1) Mandrel bent aluminum piping, turbo to intercooler (PIPE #1)(1) Mandrel bent aluminum piping, intercooler to MAP sensor piping (PIPE #2)(1) Mandrel bent aluminum piping with MAP sensor and frame bracket (PIPE #3)(1) Mandrel bent aluminum piping from MAP sensor piping to throttle body (PIPE#4)(4) Rubber well nuts 5/8” outside diameter(4) M8 x 35mm x 1.25mm thread pitch stainless steel socket head cap screws(2) M6 x 10mm x 1.00mm thread pitch stainless steel socket head cap screws(2) M8 x 16mm x 1.25mm thread pitch stainless steel socket head cap screws(2) M6 x 20mm x 1.00mm thread pitch stainless steel socket head cap screws(12) Stainless steel T-bolt clamps (2.5”)(5) 2.50” x 3.00” silicone coupler(1) 2.50” x 2.25” silicone coupler(2) Zip ties

List of Required Tools

Flat tip screwdriver13mm Ratchet or wrenchTorque wrenchDrill10mm Wrench or socket or ratchet5/16” Drillbit1/8” Drillbit5/8” Unibit or standard bitAluminum deburring tool or round file6MM Allen wrench or socket 4MM Allen wrench or socket5MM Allen wrench or socket13MM Wrench or socket5MM Wrench or socket or ratchet11MM Wrench or socket or ratchet

Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the

repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could

damage the vehicle or compromise its safety.

1

Remove sound baffle (8) PHILLIPS screws

Right side (US Passenger)

STEP 1

Figure 1

2

Remove (4) T25 screws from bumper

STEP 2

Figure 2

3

Remove passenger fender liner (2) T25 screws and plastic clips (6)

STEP 3

Figure 3

4

STEP 4 Remove 10mm bolt (socket with 24” extension) from

inside fender that attaches bumper to fender

Figure 4

5

Left side (US Drivers)

Repeat steps 1-4 on the Driver’s side of the car.

STEP 5

6

STEP 1 Center of car

Remove cowl cover (4) T27 screws

Figure 5

7

STEP 2 Remove engine cover

Figure 6

8

STEP 3 Remove air intake for airbox (2) T20 screws

Figure 7

9

STEP 4 Remove charge air hose from throttle body and sound box (not visible)

FLAT TIP SCREWDRIVER

Figure 8

10

STEP 5 Remove T27 screw from bumper at lock carrier

Figure 9

11

STEP 6 Remove coming home sensor (if equipped) and possibly the outside air

temperature sensor

Figure 10

12

STEPS 7&8 Gently pull away bumper from fender on passenger side.

Take care not to damage clips

Gently pull away bumper from drivers side. Take care not to damage clips

Figure 11

13

STEP 9 Gently pull bumper cover away from car at front,

check to make sure nothing is still connected

Figure 12

14

STEP 10 Place bumper in a safe and secure location being careful not to scratch it

Figure 13

15

STEPS11&12 Unplug horns and unbolt crash bar (4) 13mm bolts

13mm RATCHET OR WRENCH

Repeat on driver’s side

Figure 14

16

STEP 13 Remove crash bar by pulling away from car

Figure 15

17

STEP 14 Remove left and right air guides

FLAT TIP SCREWDRIVER

Figure 16

18

STEP 15 Remove charge air piping from core and turbo on passenger

side FLAT TIP SCREWDRIVER

Figure 17

19

STEP 16 Remove charge air piping from core and sound box

FLAT TIP SCREWDRIVER

Figure 18

20

STEP 17 Unplug MAP(Mass Air Pressure) sensor

Figure 19

21

STEP 18 Remove sound box (3) 10mm nuts

10mm WRENCH OR SOCKET AND RATCHET

Figure 20

22

STEP 19 Remove I/C core (1) T25 screw on drivers side

Figure 21

23

STEP 20 On the passenger side, depress clip and rotate core away

from front of car towards ground, lift up and remove

Figure 22

24

STEP 21 Remove 2.0” turbo outlet adapter (3) 5mm capscrews from

compressor housing

Figure 23

25

STEP 22 DO NOT DAMAGE O-RING! attach 2.5” turbo outlet adapter. BE CAREFUL!

MAKE SURE THE O-RING IS ALIGNED WITH GROOVE ON THE COMPRESSOR

Figure 24

26

STEP 23 Remove lock carrier support (1) T27 screw

Figure 25

27

STEP 24 Remove lock carrier support 13mm nut

Figure 26

28

STEP 25 Place short silicone coupler on turbo outlet and attach with T-bolt

clamp, tighten (do not over tighten) with 11mm socket and ratchet or 11mm wrench. If you are having a difficult time with the T-bolt clamp,

temporarily remove one of the turbo outlet bolts.

Figure 27

29

STEPS 1&2 PUTTING TOGETHER REBAR

Secure rebar in a vice or a suitable workspace for drilling.

Remove the air guide from the rebar with a FLAT TIP SCREWDRIVER.

Figure 28

30

STEP 3 Attach billet intercooler core support to two holes in rebar with

the (2) supplied 4mm capscrews (just hand tighten for now). 4MM ALLEN WRENCH OR SOCKET

Figure 29

31

STEP 4

Mark the rebar for drilling by using a 5/16” drill bit in all four countersunk holes that are in the billet support

brace (can be done by hand or by lightly drilling) 5/16” DRILLBIT and DRILL

Figure 30

32

STEP 5

Remove billet support brace from crash bar. 4MM ALLEN WRENCH OR SOCKET

Figure 31

33

STEP 6

Drill (4) pilot holes in crashbar with a 1/8” drillbit 1/8” DRILLBIT and DRILL

Figure 32

34

STEP 7 Using a unibit (Stepped Drill bit), enlarge the (4) pilot holes

to exactly 5/8” UNIBIT or STANDARD BIT and DRILL. Blow or brush off all excess aluminum from drilling

Figure 33

35

STEPS 8&9

If standard 5/8 drillbit was used, deburr each of the four holes with a deburring tool or file smooth

ALUMINUM DEBURRING TOOL OR ROUND FILE

Insert (4) rubber wellnuts into holes that were drilled

Figure 34

36

STEP 10

Attach billet aluminum intercooler core support to crash bar with (4) countersunk 6mm capscrews and (2) 4mm capscrews, torque to 18 Ft/lbs

6MM ALLEN WRENCH OR SOCKET, 4MM ALLEN WRENCH OR SOCKET AND TORQUE WRENCH

Figure 35

37

STEP 11

Attach intercooler core to billet intercooler core support with (2) 5mm capscrews (loctite recommended, torque to 18 Ft/lbs) make

sure that the baffled inlet side is to the left (passenger side) of car. 5MM ALLEN WRENCH OR SOCKET AND TORQUE WRENCH

Figure 36

38

STEP 1

REASSEMBLY PROCEDURE

Reattach crash bar (with intercooler on it) to car with the (4) 13mm bolts that were removed from it. 13MM WRENCH OR SOCKET

Figure 37

39

STEP 2

Clip air guide back onto crash bar

and clip headlight vent tube back into air guide,

secure with zip tie

Figure 38a

Figure 38b

40

STEP 3

Place silicone coupler on each side of intercooler core and use T-bolt clamp to

secure. tighten with 11mm wrench or socket 11MM WRENCH OR SOCKET

Figure 39

41

STEP 4

Remove MAP sensor from sound box and attach to intercooler pipe #3

(with bracket on it) with 5mm cap screws (do not over tighten)

5MM ALLEN WRENCH OR SOCKET AND RATCHET

Figure 40a

Figure 40b

42

STEP 5

Place silicone couplers on each end of intercooler pipe #3 with bracket on it use T-bolt clamp to secure( do

not over tighten) with 11mm wrench or socket and ratchet 11mm WRENCH OR SOCKET WITH RATCHET

Figure 41

43

STEP 6

Transfer (3) rubber bushings from factory sound box to intercooler pipe with bracket (there are three different sizes,

make sure each goes in their respective place) to remove bushing, first push out the metal inset, then push out bushing

Figure 42

44

STEP 7

Attach intercooler pipe with bracket to car with the (3) 13mm nuts that were removed from car 13MM WRENCH OR SOCKET WITH RATCHET

Figure 43

45

Place intercooler pipe #2 into silicone couplers on intercooler core and intercooler pipe #3 (with bracket on it) and use T-bolt clamps to

secure it with 11mm wrench or socket with ratchet (do not over tighten)

11MM WRENCH OR SOCKET WITH RATCHET

STEP 8

Figure 44

46

Place Intercooler pipe #4 into silicone couplers between throttle body and intercooler pipe #3 (with bracket on it) using (1) T-bolt clamp and the original worm clamp on the throttle body. Secure it with 11mm wrench or socket with

ratchet (do not over tighten) and a flat tip screwdriver on the throttle body side 11MM WRENCH OR SOCKET WITH RATCHET, FLAT TIP SCREWDRIVER

Plug MAP sensor harness into the MAP sensor.

STEPS9&10

Figure 45

47

Place Intercooler pipe #1 into silicone couplers between 2.5” billet turbo outlet adapter and intercooler, use T-bolt clamps to secure it with 11mm wrench or socket with ratchet (do not over

tighten) 11MM WRENCH OR SOCKET WITH RATCHET

REATTACH BUMPER TO VEHICLE

STEP 11

Figure 46

Congratulations! You’re done!

LIMITED ONE (1) YEAR WARRANTY

Eurocode Tuning, Inc. (EUROCODE) warrants to the original purchaser that our B8 A4/A5 Intercooler Upgrade Kit (PRODUCT) will be free of defects in material and workmanship for a period of one (1) year from the date of purchase. This Warranty applies only to the original purchaser of the PRODUCT. To obtain any warranty service, you must provide EUROCODE with proof of purchase and date of purchase acceptable to EUROCODE, such as a copy of your purchase receipt. This warranty does not cover the removal or reinstallation of the product. EUROCODE will, at its option, repair, replace or refund the purchase price of a defective component, provided you return the defective component during the warranty period, transportation charges prepaid, to Eurocode Tuning’s Service Department or a Factory Authorized Service Center.

Attach your name, address, telephone number, a description of the problem, and a copy of your sales receipt. All returns must be accompanied by a Return Goods Authorization (RGA) number and such number shall be written clearly on the outside of the box. RGA numbers may be obtained by calling EUROCODE at 1-310-294-8108 This warranty does not apply to the (i) metal finish or (ii) if the product/component has been damaged by accident, abuse, misuse, collision, modification, misapplication, improper installation, or improper service. This warranty is void if any EUROCODE serial number has been removed or defaced. Commercial or industrial use or application, or any motorsports use voids the warranty.

THE WARRANTY SET FORTH ABOVE IS THE ONLY WARRANTY. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY WHICH BY LAW MAY NOT BE EXCLUDED IS LIMITED IN DURATION TO ONE (1) YEAR FROM THE DATE OF ORIGINAL RETAIL PURCHASE OF THE PRODUCT.

No EUROCODE dealer, agent or employee is authorized to make any modification, extension or addition to this warranty.

EUROCODE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOST PROFITS, DOWN TIME OR LOSS OF USE) UNDER ANY LEGAL THEORY, EVEN IF EUROCODE WAS ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.

Some states do not allow the exclusion of implied warranties or the exclusion or limitation of liability for incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights. You may also have other rights that vary from state to state. EUROCODE reserves the right to change Product/component design without notice. In situations in which EUROCODE has changed a Product/component design, EUROCODE shall have no obligation to upgrade or otherwise modify previously manufactured Products/components.

Warranty inquires and Products returned for warranty service should be sent to:

Eurocode Tuning, Inc.Customer Service Department1908 Del Amo BlvdTorrance, CA 905011-310-294-81081-310-212-7141 International Fax