The M7 Direct Flow Intercooler (DFIC) Installation Guide

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1 The M7 Direct Flow Intercooler (DFIC) Installation Guide This information is meant only as a guide. The author of this information,, or any M7 Tuning employees assumes no liabilities for any outcomes resulting from using this information. Proceed at your own risk! It is always best to consult a certified mechanic or your local MINI Dealer before undertaking any mechanical work on your vehicle.

2

3 Please Note: Read through this entire guide BEFORE STARTING INSTALLATION. If anything seems unclear, please call our office: Monday Friday 9:00am 5:00pm EST If you require assistance please call If no one is available when you call, please leave a message or send an to: and someone will return your call. If any part of this installation seems too difficult, we strongly suggest you contact your local MINI mechanic to assist in installation or to install this unit for you. Above all else, DO NOT hesitate to call us for help! Sincerely, Team M7

4 Tools & Supplies Required: 8 mm Hex socket & wrench 10 mm Hex socket & wrench 3/8 inch Hex Socket 4 mm Allen wrench #30 Torx socket or wrench Ratchet Socket drive extension Phillips Screwdriver Masking tape Water based heavy duty cleaner product and clean rags or paper towels Estimated Install Time: 1 hour to 2 hours **This installation guide refers to MINI Cooper S models sold in the United States. If you have any questions, please call our office. This information is meant only as a guide. The author of this information,, or any employees assumes no liabilities for any outcomes resulting from using this information. Proceed at your own risk! It is always best to consult a licensed mechanic or your local MINI Dealer before undertaking any mechanical work on your vehicle.

5 Parts List: DFIC Intercooler DFIC hood scoop w/mounting nuts. DFIC Inlet duct with seals installed M6x10mm bolts -- 2 M6 flat washers Adhesive Foam Seal Kit 2 silicone boots Assembled Inlet diverter duct shown This is the correct orientation of the M7 DFIC when looking at it head-on (from the front of the car).

6 DISASSEMBLY PROCEDURE Begin by removing the stock intercooler diverter cover. Loosen and remove the (4) M6 retaining bolts using a #30 Torx wrench or driver. Remove the diverter cover

7 Using an 8mm socket, remove the (2) black horseshoe shaped brackets located towards the front of the intercooler. An extension may be useful if your tools will not fit. Remove the wiring harness from the clip at the front of the intercooler. This wiring harness will be tucked under the DFIC inlet duct at a later step.

8 To make room for the inlet duct remove the holding clip. Using a 10 mm socket or wrench, remove the retaining bolt and remove the clip that held the wiring harness in place. Leave the hose clamp in place. You only need to remove the clip.

9 Replace the M4 bolt and tighten. Torque to 30 inlbs ( **NOTE** Remove all loose debris and dirt from the intercooler, from underneath the intercooler, around the intercooler connection boots, horns and general work area. Best method is to use compresses air and a blow gun. Take every precaution now to prevent dirt and any foreign object from falling into the intake system during the removal of the stock intercooler. Use a #30 Torx driver to remove the four (4) intercooler inlet/ outlet clamps. There are eight (8) bolts in total to remove. (4) per side

10 Before removing, note that the top and bottom of each clamp has one male end and one female end. It is advised to make a small mark on each clamp with a Sharpie to identify top and bottom. Gently tap each clamp side to side with a small plastic hammer to loosen. TOP CLAMP BOTTOM CLAMP Remove the stock intercooler by pulling the unit up from the back and then towards the front of the car. It may be helpful to have someone hold the clamp bottoms to prevent them from falling into the engine bay.

11 Remove the stock black rubber bellows. These will be replaced with the new silicone boots supplied with your DFIC. **NOTE** Take a good look at the intercooler clamps before continuing. Each clamp has two parts: Top and Bottom. The top half has a straight hole without threads. The bottom half is threaded for screws. It is EXTREMELY important (to avoid frustration) that you make this distinction now.

12 TOP CLAMP BOTTOM CLAMP BOTTOM CLAMP. NOTE THREADED HOLE

13 *CAUTION* The intake horns to the supercharger and intake manifold are now open. TAKE EXTREME CAUTION not to drop anything into these open ports. This includes tools, hardware, dirt, etc.. If you do drop anything into these open ports YOU MUST REMOVE IT before reassembly. Failure to do so will cause extreme damage to you engine.

14 REASSEMBLY PROCEDURE *NOTE* If installing the optional M7 DFIC Heatshield, now is the time to do so. Attach the large silicone boot to the passenger side intercooler horn. Clamp this one side down. Attach the small silicone boot directly onto the intercooler and clamp it down. Slide the large end of the intercooler onto the larger boot and push the rest of the intercooler down into place. If you are having trouble sliding the boots in-place, use a water-based cleaning spray such as foaming window cleaner as a lubricant. Do not use oil or petroleum based products.

15 Adjust the placement of the rubber boots and the DFIC itself to reduce any connection gaps. Make sure that all ends of the silicone boots are installed correctly and the DFIC Intercooler is centered between the intake horns. This may be one of the trickiest parts of the installation. Fish the bottom parts of the inlet / outlet clamps under the silicone boots Make sure that you are installing the bottom pieces on the bottom! (See Caution on previous pages) It may be helpful to pull the DFIC slightly upwards to give you more room. Then slide the clamps in from the back of the car towards the front.

16 Attach the top clamp sections and install the factory T-30 screws. FINGER TIGHTEN ONLY! DO NOT TIGHTEN yet. Before tightening down the clamps, run your fingers around the inlet and outlet holes of both the passenger and driver s side to make sure they are sitting flat and square to the DFIC intercooler and intake horns. If the boots are wrinkled or the seal is not good, adjust the position of the DFIC and the silicone boots as required to achieve a quality seal. If all is well, tighten the intercooler clamp bolts to 40 in-lbs (4.5 Nm) and then final torque to 85 in-lbs (9.6 Nm) each.

17 Next we will attach the inlet duct. It will attach to the intake manifold using the two (2) inner-most threaded holes used by the OEM intercooler brackets. Bring the inlet diverter duct leading edge down behind the hood rubber seal and align the holes with those on the intake manifold. Tuck the foam seal neatly under the hood rubber seal as shown. Fasten in place using two (2) M6 x10mm long supplied button head screws and washers. Torque to 45 in-lbs (5.0 Nm) DO NOT OVER TIGHTEN! NO GRUNTING!

18 Next, remove the hood scoop liner. DO NOT CLOSE THE HOOD until this is removed. This requires the 8 mm socket and a Phillips screwdriver. Note: The two 8 mm nuts used to hold the scoop liner in place also attaches the back end of the hood scoop to the hood. After removing the screws and the nuts, the scoop liner will be free to fall out. Be ready to catch it after removing the last screw.

19 IMPORTANT! Thoroughly clean the newly exposed hood surface using a solvent cleaner first and then final clean with Windex or similar product. This is to ensure the foam seal adheres correctly to the hood.

20 With the paper (sticky) side up, align the 11 sealing foam along the front edge of the intercooler and the 2 short pieces over the center of the legs of the inlet duct as shown. Temporarily hold the foam in place with masking tape along the side edges or bottom face of the foam. Use only a small amount of tape so it releases when lifting the hood. Remove the paper backing strip from the foam.

21 Gently close the hood and the adhesive foam will stick to it. You may apply LIGHT pressure to the hood to make sure the foam sticks. Open the hood and make sure the foam attached. Gently push the foam to make sure it is completely stuck to the hood. Open the hood and make sure the foam attached. Gently push the foam to make sure it is applied properly from end to end. NEED PHOTO Note: The two short 2 wide pieces attach alongside the long piece at either end. (For reference, these should fit directly above the ends of the diverter when the hood is closed).

22 Remove the two (2) remaining 8 mm nuts that are holding the stock hood scoop in place. After the nuts are removed, there is a clip in the middle of the scoop still holding it in place. To remove the scoop, gently pull it upwards just enough to clear the front screws from the mounting holes.

23 Then pull the scoop out towards the front bumper to unclip the scoop. Replace the stock scoop with the DFIC scoop. DO NOT FORCE the DFIC scoop into place. Try starting with the passenger side of the scoop, then sliding in the driver s side of the scoop. If you are still having fitment issues, you may have to file one or more of the attachment holes to allow easier entrance of the new scoop s screws.

24 Forcing the scoop into place may result in unexpected damage to both the DFIC scoop and your hood. Use the four (4) supplied hardware to secure the DFIC scoop to the hood. CAUTION DO NOT OVERTIGHTEN the nuts. Light hand-tight is good enough to keep the scoop in place. MAXIMUM TORQUE IS 20 in-lbs (2 Nm) Start the engine and let it warm up. Listen for any intake pressure leaks to ensure the boots to the intercooler are sealed. CONGRATULATIONS! This is the end of the M7 DFIC Installation guide. We hope that you found this guide helpful. The final step is to go out, drive, and FEEL the difference! Enjoy the RIDE!!!

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