Page created: 2-Dec-06
Uprated Intercooler Installation
Below are a few details
of the installation as carried out by Allisports' technician at their
old and new intercoolers side by side for comparison.
larger cooling fins of the Allisport version are clearly visible.
They're also longer than the standard ones and the headers are
correspondingly more compact.
new three part silicon hose kit.
The two smaller pieces
replace identical rubber ones between the turbo and the bottom of the
intercooler. The larger one is to connect the top of the intercooler to
the intake manifold and replaces a rigid pipe with a 'T' connection from
the EGR valve that was removed during this installation.
new intercooler mounted in place of the original one.
Because of the reduced size of the headers, the top
pipe is slightly higher than before and a small piece has been cut out
of the lip of the top retaining plate. This was achieved with a grinding
wheel in a matter of minutes in the workshop.
from above of the new silicon hoses in place.
The elbow from the turbo is connected to a steel
pipe that routes the air towards the bottom of the intercooler. This
pipe is a re-used original part but the rubber cladding has been
stripped off to aid cooling.
New hose clips were used throughout.
view of the new pipes.
The black enameled steel plate used to blank off
the hole where the EGR valve was mounted can be seen on the exhaust
The short silicon hose connection to the bottom of the intercooler
can just be seen in the lower left of the picture.
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