Mini R53 Top Mount Intercooler Fitting Instructions

Transcription

1 Parts Pro Alloy Intercooler 2 x M6 x 12 Hex head bolt 2 x M6 Washer 1 x 30-45mm Hose Clip Tools Required T30 Torx Bit 12mm Spanner 11mm Spanner Deep 10mm Socket 11mm Socket 8mm Socket Extension bar Ratchet Phillips screw driver Small flat blade screwdriver Hacksaw Angled pick tool (Not essential) Gasket Sealant

2 Before you begin the installation check all parts against kit list. This intercooler kit can be fitted without the use of a ramp and the car will not need to be jacked up. The standard intercooler can be removed and the new unit installed with just the bonnet open. Removing the Standard Intercooler Undo the 4 x T30 torx bolts securing the plastic cover on the standard intercooler. Note - You may need a 12mm spanner to stop the front 2 T30's from spinning. - Remove the 2 black brackets on the front. Undo 8 x T30 torx bolts on the 4 hose clamps then take the top of the clamps off.

3 Remove the intercooler. The intercooler rubber boots may come off with the intercooler. Keep the offside boot as you will need this to fit the new intercooler (larger of the two boots). Using an 11mm spanner undo 3 x nuts securing nearside Intercooler horn to inlet manifold. Undo 2 x 10mm Hex head bolts securing the black bracket to the throttle body. Remove these bolts to allow sufficient movement to remove horn and slide the new intercooler in.

4 Remove top hose clip on re-circ valve, using a angled pick or small flat blade screw driver. Tip; slide a flat head screw driver between the pipe and silicone hose and spray a small amount of WD40 to help the hose slip off. Gently push the throttle body downwards, pushing the bypass valve hose off. Tip; Care should be taken to not push the throttle body assembly down too far as it will pull the inlet off the supercharger and will cause running issues. Slide Supercharger horn off studs. Remove bypass valve from the horn - Undo the 3 x 10mm bolts. Modifying Bonnet Scoop Trim First we need to remove the scoop panel in the centre on the underside of the bonnet. Undo the 2 Phillips screws at the bottom and then 2 x 8mm Nuts at the top. Cut part of the plastic trim off as shown - A hack saw will be fine for this.

5 Attaching bypass valve to Pro Alloy Intercooler Use the standard 3 x 10mm bolts to secure the bypass valve to the new Pro Alloy intercooler. Note which way round the bypass valve is mounted in photo below. Fitting the Intercooler Reattach boot and nearside brackets then tighten the clamps mounting the boot to the horn leaving the intercooler side loose. We would recommend applying a smear of gasket sealant onto the face of the plenum flange before positioning the intercooler into its final location.

6 Put supplied hose clip over bypass hose in readiness for intercooler fitment. Tip; Wipe inside of the boot and bypass valve silicone with WD40 to help slide on. Tip; Make sure the inside of the end tanks on the intercooler are clear of all debris (for example; packaging material, swarf, fluff or grit). First locate the bypass valve in the silicone hose. Once in, slide the flange on the intercooler over the plenum studs at the same time as slotting the other end of the intercooler in the boot. Tip; A smear of WD40 on the inside of the boot will help the intercooler slide in Refit the 2 x 10mm headed bolts in to throttle body black bracket Tighten the new bypass valve hose clip, ensure its not rubbing on the water hose.

7 Tighten 3 x 11mm blots on inlet side of the intercooler using the original nuts. Tighten 2 x T30 on boot clamps Take off black plastic bracket off wire as its not needed any more

8 Attached wire mount to M6 boss on the bottom of intercooler using the supplied M6 x 10mm hex head bolt and washer. Reattach P clip that holds water hose in place. Finally secure intercooler offside front bracket using original bolt. Job done, make sure all connections are tight. Remember to remove all tools from engine bay before shutting the bonnet. Take for a small trip out then recheck all connections again. You may also be interested in the Mini R53 Alloy Header Tank Available in either satin silver or textured black. Visit for more info.