You'll need a socket set in both metric and standard measurements, a flat-head screwdriver, and hose sealer tape (available from auto parts stores).
1. You can raise the car, or leave as is. If the car is not raised, it will be more difficult to reach the bottom bolts. Below is an image of the stock intercooler.
2. From the top, you'll need to remove the two nuts on the bracket and the bolt attaching the intercooler to the radiator. They are all 10mm in size.
3. The fan will need to be disconnected. There are two 10mm bolts attaching the fan to the radiator and intercooler. The plug should be undone and the cable removed. Once all of these are removed, lift slightly to detach from lower mounts; the fan should remain free.
4. From underneath, you'll need to remove the large bolt (14mm) and the two smaller bolts (10mm). This can be done from above if you are able to feel the bolts.
5. Once everything is clear, use a screwdriver to loosen the hose clamp holding the hoses to the intercooler. Remove the piping. (This can be very difficult due to the sealant tape. For the lower hose, it's easier to use brute force if you're under the car. For the upper hose, disconnecting it from the turbo as well and pulled it off the intercooler once the intercooler was removed from the car is a little easier.)
6. Once everything is disconnected, remove the intercooler from the top. Below are images of the stock intercooler next to the Circuit Sport intercooler.
7. Below are images of the intercooler location. (Notice the fan is still there. Also notice the large hole at the bottom center of the image.)
8. Slide the new intercooler in place. The large post on the bottom will insert into the large hole in the bottom center of the above image.
9. From the top, attach the bracket using the two 10mm nuts, making sure that the notch slides onto the radiator.
10. From underneath, fasten the two 10mm bolts to attach the intercooler to the radiator. (The 14mm bolt is not used during reinstall.)
11. Also from underneath, mount the lower pegs on the fan. Below is an image of one of those pegs in the correct slot.
12. From the top, fasten the two 10mm bolts to attach the fan to the radiator and intercooler. Reattach the plug and wire-holders.
13. Wrap both piping attachments with sealer tape. Attach the intake piping and clamp tightly.
Below are images of the installed intercooloer.
Possible issues:
http://www.msprotege.com/forum/showthread.php?t=76376
1. You can raise the car, or leave as is. If the car is not raised, it will be more difficult to reach the bottom bolts. Below is an image of the stock intercooler.
2. From the top, you'll need to remove the two nuts on the bracket and the bolt attaching the intercooler to the radiator. They are all 10mm in size.
3. The fan will need to be disconnected. There are two 10mm bolts attaching the fan to the radiator and intercooler. The plug should be undone and the cable removed. Once all of these are removed, lift slightly to detach from lower mounts; the fan should remain free.
4. From underneath, you'll need to remove the large bolt (14mm) and the two smaller bolts (10mm). This can be done from above if you are able to feel the bolts.
5. Once everything is clear, use a screwdriver to loosen the hose clamp holding the hoses to the intercooler. Remove the piping. (This can be very difficult due to the sealant tape. For the lower hose, it's easier to use brute force if you're under the car. For the upper hose, disconnecting it from the turbo as well and pulled it off the intercooler once the intercooler was removed from the car is a little easier.)
6. Once everything is disconnected, remove the intercooler from the top. Below are images of the stock intercooler next to the Circuit Sport intercooler.
7. Below are images of the intercooler location. (Notice the fan is still there. Also notice the large hole at the bottom center of the image.)
8. Slide the new intercooler in place. The large post on the bottom will insert into the large hole in the bottom center of the above image.
9. From the top, attach the bracket using the two 10mm nuts, making sure that the notch slides onto the radiator.
10. From underneath, fasten the two 10mm bolts to attach the intercooler to the radiator. (The 14mm bolt is not used during reinstall.)
11. Also from underneath, mount the lower pegs on the fan. Below is an image of one of those pegs in the correct slot.
12. From the top, fasten the two 10mm bolts to attach the fan to the radiator and intercooler. Reattach the plug and wire-holders.
13. Wrap both piping attachments with sealer tape. Attach the intake piping and clamp tightly.
Below are images of the installed intercooloer.
Possible issues:
- If sealer tape is not used, it is likely that boost pressure will vent out the connections. The piping will not clamp tight enough at the connections to prevent this. If you hear a sound of pressure being lost, this is the cause. Other symptoms include fuel cut at low boost and stalling.
- One some models, one of the lower pegs for the fan will not match up with the spot on the intercooler. This is okay and can be ignored.
- With the increased airflow, it may be a good idea to reset the ECU.
http://www.msprotege.com/forum/showthread.php?t=76376
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