E92 Intercooler Upgrade |
|
E92 INTERCOOLER UPGRADE This DIY is just an idea on how it can be done and I am not responsable for anything. Do it at your own risk . Make sure you have a standart selection of automotive tools ... You will need for sure:
1. First thing you need to do is to put your car on the jack stands to have free work space.
2. You will have to remove your front bumper, wheels, both driver and pass. side inner fender covers, and factory plastic dust pan. Here is very good DIY on how to remove front bumper. http://www.bmwteam.net/board/index.php?showtopic=10148
3. After those parts are off , remove the both the factory boost tubes that connects to the intercooler on the intercooler side by removing the springs retainers. driver side
passenger side
4. Remove factory intercooler by uncliping 2 black clips and
unscrewing two Torx T25 bolts from the core support
Torx T25 bolts
Now intercooler is off ... here you can compare the size of
the Stock intercooler to Spearco
Stock vs Spearco
5. Remove the pass. side turbo to intercooler boost tube. To remove the factory hose clamp, find the seam and inseart a flat head screwdriver and pry apart. Make sure not to damage factory silicone hose. I used that orange tool with the small hook to pull it off. Make sure to pull it very easy. Boost tube
6. Disconnect the intercooler to BOV pipe from the fan shroud. No picture but you will see that clip on the pipe later 7. Loosen this clamp
and remove that pipe from the bottom of the vehicle ( turn it clock wise ) turning
pipe is off (you can see that clip from step 6 here)
8. Here is the fun part. Now you need to trim the core
support using an air body saw or dremel. You need to use a caliper and set
it to 0.75" (3/4) , then place the caliper against the back enge of the
core support and make a line across the entire bottom part of the core
support
than trim it
9. Now you need to try to fit the new intercooler in, to see if you did a good job. 10. Install the supplied 45 degree silicone hose to the factory pass. side turbo to intercooler pipe. Slide two supplied hose clamps onto 45deg. silicone hose loosely.
Now install second supplied silicone hose onto the driver side of the new intercoller with 2 hose clamps ( you can tight one down and leave the second loose)
11. Now you can install the new intercooler into the vehicle. Slide the other end of the previously installed 45 deg. hose onto pass. side inlet of the intercooler. Make sure the " L " brackets that are welded to the intercooler slides onto the back of the factory fan shroud. ( No pics of the L brackets, sorry, but you will see them on the intercooler) pass side 45 degree silicone hose
sliding it in
driver side
12. Make sure everything fits right and then you can screw the intercooler to the core support using those two factory Torx T25 screws. 13. Here it is
14. Now another FUN part. You will need to insert the one ( longer straight) end of the supplied boost tube into the other end of silicon hose coupling( driver side ), that was previously installed on the driver's side new intercooler inlet. The other end of supplied boost tube you will need to insert into the hose on the factory BOV securing using the factory hose clamp. To do all that, I would recommend to take off two parts of your intake, so you can have more space there. part of the intake off
supplied silicone hose that you mounted on the intercooler's inlet (driver side)
15. Now tight everything down and make sure all the connections are good. 16. Put everything back and go and test your new Spearco intercooler.
|
