I am thinking about buying a PFS medium stock mount intercooler and I am having some quick questions. Will the kit fit with stock air intake system (airbox/piping), stock twin, and stock battery location? Do I need to modify my A/C system or re-route my A/C lines? How difficult is it to install? How efficiency is it comparing to other SMICs? Thanks for the help.

 

Just so there's no confusion on which intercooler, my comments regard this one:



*It does NOT fit with the stock intake. PFS offered their own mated intake system with it. That intake operated similarly to the stock intake and has provisions for all stock hoses. If you don't have that, it DOES work with most open intake systems.
*NO fitment problems with stock twins and airpump.
*It DOES fit with the stock battery and tray.
*No issues with, or modifications needed with AC or PS.

 

In case you care, it does fit with an M2 intake. If you have a Koyo rad, watch out where the duct sits. You don't want it pushing down on your fan motor. I burned out 2 fan motors that way.

As Sgtblue mentioned the IC usually came as a CAI + SMIC kit. I have the intake sitting around if you're interested.

 

What's my intake options if I don't have a M2 or PFS intake system? Does the ebay intake pipe and cone filter work with the intercooler? Is it possible to modify my stock intake to work with the intercooler?

 

Most open intakes I think will fit. I'm fairly certain Fighter's garage. I believe Apex'i but it's a little crowded. Not sure about Greddy or Pettit. Have you done any searching?
Yes.
No.


If you buy the PFS IC, you might also see what red_dragon wants for his PFS intake. I modified mine to source most air from the nose, similar to a M2 box. Lacks a little of the bling factor but it performs well....better than an open element IMO.

 

Even with the Fluidyne radiator, which is lower profile, you may run into fitment issues. For any SMIC application with a duct, I would recommend a Ron Davis/AWR/Mazdaspeed radiator for headache free installation; its core size is similar to OEM and therefore thinner than any aftermarket application. It is a bit pricey though.

 

I have a Fluidyne and had no issues.

 

I bought mine here for $380. It came with a duct without the channel to the air box (which I preffer). My battery, air cond, are still in ther stock location (no mods nessessary). I already had an intake from Pettit racing. The stock air box has to go.

One more thing nobody mentioned is that the Air separator tank has to be moved from its stock location. It would be a good time to upgrade to a metal one. If you keep the ast stock you have to lengthen some of the coolant lines comming from the bottom right side of the radiator. Shorten the line comming off the thermostat housing in order to mount the ast on the PFS SMIC flange between the pipes.

Below are some pictures of this intercooler install

 

The rest. In the last picture you can see I did'nt take into consideration the AST. I temporarily kept in place with black zip ties till it could be fixed right.

Its a great choice if you are still running your twins. I've seen some impressive intake temp drops with this intercooler. Compared to the stock IC there is sooooooooo much better flow and my engine sees the 12psi every time with the PFS SMIC. Unlike the stock one, there was a lot of boost drop.

Hope this info helps

 

IMO, the location of the mounting bracket on the PFS was done only with the stock AST in mind. The metal AST I had didn't come close to fitting and most pictures you'll find of the PFS mounted include some type of modification. You'll notice in the picture above the AST was eliminated with the Series 5 FC filler neck and cap. It's marginally harder to burp when changing coolant, but no other issues. It's one less thing interfering with air flow out the back of the IC and a bit cleaner looking.

 

I have the Pettit racing AST already, seems like I will have to relocate it somehow. Thanks for all your precious information and pictures. I really appreciate it.

 

I just re-installed my PFS IC, after being newly powdercoated(!), and my Kinetic AST (I think he modeled it after the Pettit ones) is attached to the tab on the PFS. The holes don't match so I just used foam to pad the contact point and used two 14" cable ties to attach it. The AST barely touches on the IC as you can see. The stock coolant lines were contorted to allow it to fit without kinking - they are rather durable and the connections remain strong with no leaks. Make sure you wire tie the Radiator to AST coolant line to the fan housing underneath if you do this as that line can bend down into the fan path. (I learned this the hard way.)

I was afraid the wire ties wouldn't be strong enough but it's pretty solid. Besides, the three coolant hoses suspend and support the AST too. I've had it on there for awhile now - I don't think it's going anywhere. I haven't exactly done a "slam on the brakes" test yet though. Also, make sure the coolant line from the AST to the coolant filler neck doesn't bend into the spinning belt. It shouldn't as it makes a nice "S." (I wire tied this one too, just in case.) The AST fits so well there that the other two coolant lines can still attach to their clips on the chassis near the battery tray.

The IC install is pretty straight-forward. It's much easier to do with a loosened y-pipe air tube and a completely removed elbow. You'll need a helping hand to position the AST as you lower the IC. Don't forget the clamps! (Sooooo much fun to realize you forgot them the first time.) Have fun and backchannel if you need more help.