Ok guys and girls, welcome to my guide to fit a universal type intercooler to your mk5 cupra,Boc ,fr. My car is a facelift mk5 so there maybe some small differences but nothing major.

You need

550x140x65mm intercooler

2x 90* bends with 57mm internal diameter

2x 57mm alloy joiners

4x 60-70 mm hose clips

And it gives you this, the kit built up (will need trimming etc)

Right I found there is quite abit more room for a much taller cooler, not sure why the size I bought was recommend but there is soo much more headroom to go much bigger.

d1b29144c91cb8af43ba019492eb5406.jpg


All of the above came to £95 and my 50mm-70mm hose clamp came to £7, you need 4 clamps as you can re use 2 original clamps

So that's the kit and now you need to fit it.

I taped my car up to protect headlights, bumper etc etc and I suggest you do the same (my cars only done 2k miles)

Firstly lift the bonnet, there are Slam panel clips x4

98f4001a96475fc26a1a03f5301e91e6.jpg


Next there are Wheel arch t25 x4 each side

5990592a1eec233724bd953a87f06f6a.jpg


And then X2 t25 under the bumper each side

801b3dc5d50336560864fefee003a7e6.jpg


Pull bumper outwards from arch working your way towards the light each side and it will reveal 1x t25 inner inner arch screw

0700c9972e544bd321aa193177a6aedd.jpg


From here you can undo the fog light connectors

no picture.

Pull bumper forward and hear it unclip, all fixing screws should be out but don't go too mad just incase you car is different

Undo headlight washer feed if you have them and unbolt pas side washer and feed the water supply through and out the way

a7a2bc9db125e6f8e77da0da61c2c95d.jpg


Remove bumper

52b6dcbb004685647014dacf5b07f139.jpg


Disconnect outside temp sender from its housing and tuck out the way

a9e213cf368b9928d39f9a88def64ff6.jpg


Remove headlight 5xt30 each head light remove and unclip wiring (these are really hard) there are 5 bolts make sure you get them all, then remove

Unbolt crash bar 3x 13 and 1x10 each side

fe9c7f421258f550d02d38111b24e5c1.jpg


Unclip bonnet catch wiring and unclip the loom from slam panel

a797adf1e349fd77380775dc8a4cf049.jpg


7ed8918074e857240b7e640afadd140a.jpg


Unclip air box feed

6fc7d60b04990df642a720f64ed91fd0.jpg


1xt30 each side front brace/slam panel

e78ae1372ca094bfb9b74b7e746c0b98.jpg


Unbolt bonnet latch 2xt30, unclip bonnet catch loom and release cable from slam panel,lift catch out and feel both loom and release cable toward the catch to allow you to pull it up to work on it. Remove bonnet cable from catch and unfeed out of slam panel and put it out the way, re locate bonnet catch.

b4fab22e234d532705593549e4123026.jpg


cf3d8f8afaf34ac595c5380afa410d93.jpg


4b7b66af15a25ad26df658253220f6d9.jpg


Rescuer your bonnet, your bonnet stay in attached to your slam panel and we are going be removing it from the car shortly

We are now removing the frame, undo the top 10mm bolts 1 each side and tilt the frame forward, this will detach the condenser and rad from the top part of the frame. Now pull the rad up and push downwards on the frame, this will un locate the locating pin/clips at the bottom and remove frame

c1b44f815dcbf86e785234097809fd1c.jpg


Undo hose clips (you can reuse these) and detach from intercooler. To remove the Intercooler on the pas side there is a clip on the front and back that need leavening out and pushing down, the intercooler sides out on the drivers side.

85153d972e6dab016a51d87ddaf37419.jpg


0a2b8c1dc5258cf28d0a44a68025ff8c.jpg


Your need something to prop the rads up.

99c195a3951eb2c43a9599079446ad4f.jpg


We are now going to fit the intercooler .

I decided I wanted to fit the intercooler as far away from the rad as possible so I cut the top section of the intercooler cradle away, you will see this allows you to bring the intercooler forward and will show the intercooler more.

78422c48d6a2cd9b01dfa21a247080b4.jpg


Cut this


fa0d165dd35f4c56bc3f7d0798a575ec.jpg


So it's like this

5af14f5ed1cf9202cb4562b167b6fd51.jpg


Next we marked up the cradle and bolted the intercooler to it, I used spacers to lift the intercooler and allow the bottom intercooler fins to get air flow.

05dca11760ec20a0547d02062134c1bb.jpg


273898287dfe2e1909bfdb47dbdcb7bb.jpg


Refit the front frame to the car and re locate the rad, make sure everything lives back where it used to and fits correctly then refit the 2x top 10mm bolts and put your bonnet stay back up

c4e8b2afb4ba5b7547d39f72ee61b84b.jpg


588160ebc92b1ce5662a4d0e220934a8.jpg


Remove the horn 1x13mm bolt so you have room to cut away the intercooler cradle

e375a30fb484584f1c55f9fe822db2db.jpg


We now need to cut quite abit away to run the new intercooler pipes

Here is pas side pics

448467a67de2e3801b59937117b78983.jpg


379552e8f4bb14379d86101d14761378.jpg


The end connecting to the intercooler needs triming down (trial and error with it)

On the drivers side both ends of the 90 pipe needed trimming and I found reversing the standard intercooler pipe so it look like this makes a neater and straighter run

cd8f416d323714e6cd9c31ffd80b3d0d.jpg


08531b914016fc6aaf737462569ea7b2.jpg



Cut away the intercooler cradle

3b91fde639b3c92c80669c348bc46f08.jpg


Fit pipes like this (trim both ends of 90* pipe

aa7d6d909ac2906f96ba447a897cea4d.jpg


aaf71538466d263d1fae7afdacf800d8.jpg


Make sure all your pipes are tight and put the thing back together in reverse of the dismantle.

7c77a207d942c252a6305c610f0d02fe.jpg


Hope this helps

Please if your selling these kits do not use my text or images.
Author
turboboy
Views
1,394
First release
Last update
Rating
0.00 star(s) 0 ratings
Nimbus hosting - Based solely in the UK.