WES_393
DSM Wiseman
- 3,814
- 97
- Jun 6, 2011
-
Colo Spgs,
Colorado
Hey Tuners, I recently installed my Punishment Racing FMIC and I decided I should post it up to share. I couldn't find anything like this so I apologize if I'm posting redundant info. This isn't really a how-to (although I wouldn't mind submitting it to tech with more pics), it's more of a little guide for those who have never done such a mod. So here goes.
This is what the kit looks like right when it arrives are your door. It would be a good idea to go through and inventory the parts to make sure it's all there.
If memory serves me, you should have:
11x 2.5" T-bolt Clamps
3x 2" T-bolt clamps (only one will be used if running 14b/16g turbo)
3x Straight coupler
2x 45* couplers (one longer than the other)
1x 2" to 2.5" reducer coupler (for use with 14b/16g style outlet)
1x 2" coupler (I believe this is used for the T25 so don't be alarmed if you can't find a place for it)
1x J-pipe (again, for use with 14b/16g turbo)
1x Knockoff purple BOV with gasket, bolts, and hose (under the foam mold)
If it looks like you have everything, then start with a pre-assembly. This is good practice with any "kit" you'll be installing. Here is what it should look like once pre-assembled.
Now, I installed the core first. I would recommend doing so in order to have a good reference for how the pipes "fit" together. This is the core. This thing is actually pretty massive.
Compared to my old ChinaBay intercooler.
The intercooler kit doesn't come with bolts for mounting. I went to Ace a while back and just bought a few of every metric bolt they had. So unfortunately I can't tell you what size they are. I THINK they were something like M8-1.25, but I would suggest taking the intercooler to your local hardware store and finding the correct size and length.
Either way, here it is mounted. You can retain the stock bumper bar with some clever modification, but I trashed mine long ago. You will use the stock mounting holes for the bumper beam with the correct size bolts to mount the intercooler. I personally used some spacers (1/2" thick nuts) to raise up the core a tiny bit. The 2ga bumper seems to be a bit higher off the ground than 2gb so I wanted to make sure the core wasn't sitting below the bumper.
Piping was pretty straight forward for install. Stick to the pre-assembly and you'll shoot right through the install. Giving the couplers a little spritz of water will make the pipes slide in much easier. I would also suggest using the shorter 45* coupler to connect the BOV flanged pipe to throttle body elbow. This way you can use the longer 45* elbow on the lower pipe that connects to the BOV flange equipped pipe. It makes bridging the gap much easier.
I had also heard rumors that the stock fans need to be "trimmed" to fit the J-pipe and it's corresponding pipes. Even though I'm using a Spyder GS slim fan, you can see for yourself that this is not true:
My BOV with a fancy Home Depot spa hose for the recirculation fitting.
One thing you'll notice right away if your still on the internal wastegate: The barb fitting on the lower intercooler pipe is 3/8". Your boost controller and wastegate nipple are close to 1/4". This is obviously a problem.
I went down to Home Depot and picked up a 3/8 x 1/4 barb fitting, a 1/4 x 1/4 barb fitting, and a 1/4 coupling. With some Teflon tape this ran me about $10. Now you can run 3/8" hose to the junction and then 1/4" hose to your boost controller. End result:
Now for the scary yet fun part: Modding the bumper. Right off the bat I took out the metal bar in the chin of the bumper. The inside of the chin was already shaved form previous intercooler. I personally see no point in buying such a large core if your going to be hiding half of it behind plastic. The mustache mod is as easy as putting the bumper up to the car, marking where the intercooler begins on both sides, drawing a guide line at a 45* angle and one straight across, and then cut. I didn't want the yellow plastic to show, so I repainted the whole bumper with factory matched paint. End result:
My thoughts on the kit: For the price, you really can't beat it. I realized I was heat soaking my intercooler pretty quick at 20psi on a small 16g. With just installing this intercooler the amount of knock has been reduced extremely (still have some tuning to do) and throttle response went through the roof. My turbo spools quicker, the BOV is very decent as far as sound/looks/function, and it just overall cleans up the engine bay.
I sure hope this helps for anyone looking for a quick guide on what expect. Comments, questions, suggestions, gripes, etc are all welcome.
This is what the kit looks like right when it arrives are your door. It would be a good idea to go through and inventory the parts to make sure it's all there.
You must be logged in to view this image or video.
If memory serves me, you should have:
11x 2.5" T-bolt Clamps
3x 2" T-bolt clamps (only one will be used if running 14b/16g turbo)
3x Straight coupler
2x 45* couplers (one longer than the other)
1x 2" to 2.5" reducer coupler (for use with 14b/16g style outlet)
1x 2" coupler (I believe this is used for the T25 so don't be alarmed if you can't find a place for it)
1x J-pipe (again, for use with 14b/16g turbo)
1x Knockoff purple BOV with gasket, bolts, and hose (under the foam mold)
If it looks like you have everything, then start with a pre-assembly. This is good practice with any "kit" you'll be installing. Here is what it should look like once pre-assembled.
You must be logged in to view this image or video.
You must be logged in to view this image or video.
Now, I installed the core first. I would recommend doing so in order to have a good reference for how the pipes "fit" together. This is the core. This thing is actually pretty massive.
You must be logged in to view this image or video.
Compared to my old ChinaBay intercooler.
You must be logged in to view this image or video.
The intercooler kit doesn't come with bolts for mounting. I went to Ace a while back and just bought a few of every metric bolt they had. So unfortunately I can't tell you what size they are. I THINK they were something like M8-1.25, but I would suggest taking the intercooler to your local hardware store and finding the correct size and length.
Either way, here it is mounted. You can retain the stock bumper bar with some clever modification, but I trashed mine long ago. You will use the stock mounting holes for the bumper beam with the correct size bolts to mount the intercooler. I personally used some spacers (1/2" thick nuts) to raise up the core a tiny bit. The 2ga bumper seems to be a bit higher off the ground than 2gb so I wanted to make sure the core wasn't sitting below the bumper.
You must be logged in to view this image or video.
Piping was pretty straight forward for install. Stick to the pre-assembly and you'll shoot right through the install. Giving the couplers a little spritz of water will make the pipes slide in much easier. I would also suggest using the shorter 45* coupler to connect the BOV flanged pipe to throttle body elbow. This way you can use the longer 45* elbow on the lower pipe that connects to the BOV flange equipped pipe. It makes bridging the gap much easier.
I had also heard rumors that the stock fans need to be "trimmed" to fit the J-pipe and it's corresponding pipes. Even though I'm using a Spyder GS slim fan, you can see for yourself that this is not true:
You must be logged in to view this image or video.
My BOV with a fancy Home Depot spa hose for the recirculation fitting.
You must be logged in to view this image or video.
One thing you'll notice right away if your still on the internal wastegate: The barb fitting on the lower intercooler pipe is 3/8". Your boost controller and wastegate nipple are close to 1/4". This is obviously a problem.
I went down to Home Depot and picked up a 3/8 x 1/4 barb fitting, a 1/4 x 1/4 barb fitting, and a 1/4 coupling. With some Teflon tape this ran me about $10. Now you can run 3/8" hose to the junction and then 1/4" hose to your boost controller. End result:
You must be logged in to view this image or video.
Now for the scary yet fun part: Modding the bumper. Right off the bat I took out the metal bar in the chin of the bumper. The inside of the chin was already shaved form previous intercooler. I personally see no point in buying such a large core if your going to be hiding half of it behind plastic. The mustache mod is as easy as putting the bumper up to the car, marking where the intercooler begins on both sides, drawing a guide line at a 45* angle and one straight across, and then cut. I didn't want the yellow plastic to show, so I repainted the whole bumper with factory matched paint. End result:
You must be logged in to view this image or video.
You must be logged in to view this image or video.
My thoughts on the kit: For the price, you really can't beat it. I realized I was heat soaking my intercooler pretty quick at 20psi on a small 16g. With just installing this intercooler the amount of knock has been reduced extremely (still have some tuning to do) and throttle response went through the roof. My turbo spools quicker, the BOV is very decent as far as sound/looks/function, and it just overall cleans up the engine bay.
I sure hope this helps for anyone looking for a quick guide on what expect. Comments, questions, suggestions, gripes, etc are all welcome.
