How To - Install New Intercooler

BLK GXP · 09-10-2007, 11:50 PM

I installed the new RPI intercooler the other day, and figured I'd share the experience.
I have a lift, but this can be done on jackstands also.
The front fascia needs to be removed to do this, but that's not as hard as I thought it would be. There are lots of screws, so remember where they go. All the screws are either 7mm or 10mm. There are also some push-in fasteners that will have to be pried out with something. I used diagonal cutting pliers, but anything that can get behind the head of these to pry them out will work.

The first thing is to get the IC pipes disconnected and out of the way. To do this, remove the four 10mm screws that hold them in and loosen the lower hose clamps on each side. The pipes can now be pulled free of the IC.

Next step is removing the Fascia and plastic under it. To do this unplug the wiring harnesses to the lights, and take out nine 7mm screws and two 10mm screws on the topside with the hood open.

At the front inner edge of each wheel well, there are four 7mm screws that need to come out.

The marker lamps can't be unplugged until after the fascia is completely loose.
Now you have to move to the underside of the car. There are four 10mm screws and 8 push-in fasteners on the bottom to be removed.

The plastic under the intercooler gan now be pulled down from under the car. Next gently pull the bumper fascia away enough on each side to disconnect the marker lamps mentioned earlier. Now the whole front fascia can be pulled off and set aside. The IC is now exposed. There are 2 brackets held on with one 10mm screw each that need to come out next.

There are two 10mm screws on each side of the intercooler to be removed. Be careful, as when these 4 screws are out, the intercooler will want to drop out.

Here are the two intercoolers side by side. The new one is a few pounds heavier, but the increased flow, and better cooling is supposed to reap more power.

the clips on the original IC need to be transferred to the new one.

Now bolt the new IC in place of the old one.

Re-install everything else in the reverse order of removal. Be sure to check the alignment of the body lines before tightning the fascia screws.

when you're done you can't really even see any difference visually.

I don't plan on any dyno tests, but RPI claims 25hp consistently. They also said to use the stock airbox with a high flow element. I had the Fujita intake tube on, but re-installed the stock box, and it does indeed run better with the stock box,so far. I may be selling the Fajita.

normsf · 09-11-2007, 10:52 AM

Hello very well done and a great job of documention. Thanks Norm www.normsfiberglass.com

NightwingII · 09-11-2007, 04:29 PM

HOw much did you pay for it if you don't mind me asking?

BLK GXP · 09-11-2007, 04:50 PM

Quote:

Originally Posted by NightwingII

HOw much did you pay for it if you don't mind me asking?

I paid $850 plus shipping directly from RPI. I was going to do this or the BSR tune, but I chose to let some time pass on the tune so they can work out the bugs. Time will tell if it was worth it.

gary · 09-11-2007, 07:47 PM

Beautiful job of explaining and documenting the procedure....Thanks!
Gary

quad4racer · 09-11-2007, 08:05 PM

They claim 25 hp and said the stock air box is better than a cold air intake?
Does this sound right to anyone? How could the stock air box make more power?
enrico

turbo4 · 09-11-2007, 08:29 PM

They are right. GM spends a lot of time designing there intake and exhaust systems to flow the max they can and also keep down on the noise. I went throu the same thing on my CTS V. We tried aftermarket CAI's and Cat back exhaust systems, and checked them on a dyno (before and after) and they showed very minor improvements in HP & TQ. Stock intake with a K&N filter is the way to go.

BLK GXP · 09-11-2007, 08:37 PM

They claim that thier testing shows the aftermarket intake actually draws in hotter air than the factory box. they Also claim the surface area of the conical filter is less than that of a high flow stock replacement filter. I took a long drive with the Fujita on there, and at first it seemed fine. After a while of driving, ( I drove 200 miles to the Bloomington cruise-in saturday.)The car would not rev above 3k-5k rpm. The next day, I put the stock box back in. I just took a 2 hour drive thru the hills around here and it drives great. I can't vouch for their logic, but the result convinced me.

BlackCatForge · 09-12-2007, 10:29 AM

I just glanced through this thread briefly, but I didn't really see your impression of your new intercooler. This is a product I had been considering, too. Anyone have any thoughts on how a GM service shop would feel about this having been installed? Warranty issues?

Solman · 09-12-2007, 10:48 AM

Don't tell them, use the instructions up above and do it yourself. It looks easy to do.