Intercooler problem
 

During my rebuild, I decided to upgrade the radiator. Well the upgraded radiator sits where the stock rad. is. This took up too much room so know my intercooler duct for my PFS intercooler doesnt fit. After driving for a while the intercooler gets hot, i mean hot. (put your finger on it for couple seconds and it will burn you) I have only got on it once because of this and only got 6psi. Is it because the air is so damned hot that I won't build boost? Is there another duct that will fit with the upgrade radiator in place also? I am going to get a frontmount soon, but just dont have the funds as of now. So what should I do? I will take a pic and attatch it right now.


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oops

pic #1

pic #1

For the intercooler to work it must have cold airflow from ducting. A stock one with ducting is better than an aftermarket one without. Duct it somehow...

Are you sure you can't just jam that sucker down there?I have a M2 intercooler and I have to shuv the duct down into it's spot THEN put the intercooler in. Howver I don't have a thicker rad. and I don't have a PFS intercooler and really I don't know anything:D

It's hard to tell from look at "intercooler - duct.jpg" because you have the duct upside down. Are you sure you have the correct duct? The PFS i/c is meant to go wtih the PFS intake bax, which has a large round hole on the intake pass side for a coupling...

Can you take a better pic? I just helped a friend finish up an install on a PSF intake box/intercooler....

I am positive that it is the correct duct. I used it that way for 6 months without the bigger rad. I will take the intercooler off and try to ram the duct in. I will take pics of that.


On the intercooler - duct picture I was just showing that I can hardly even get the duct in. I didnt try to put it in at that time.

What radiator did you go with?

This is easy. You may need to repostion the radiator so that it tilts forward more. The extra core thicknesss on aftermarket radiators goes toward the fan shroud/IC duct side.

Two ways to gain clearance:
Where the mounting tabs attach to the side of the radiator, take a dremel and slot the holes in the bracket so that the radiator will sit lower in the front when installed.

OR remove the rubber isolator where the radiator mounts in the front - put some rubber pad on the tab where the rubber isolators and use bolts.

For the CWR IC to work with a Koyo rad, both these mods were req'd for proper clearance of the duct. Take your time and look closely at how the parts fit together to determine exactly what part is causing an obstruction.

Jack

from looking at your pic of the duct, it should be turned around with the hole on the opposite side, not right next to the battery. i have the pfs IC and intake and that hole is meant to connect to the intake box.

Yea I know I have the duct backwards, I just put it there for reference to see how tight it is. I am about to go and take the intercooler off and look around. Wish me luck...