almost finished installing a forefront "big" D22 intercooler.
its been a little interesting. we had some issues with bumper clearances. i slotted the mounts a bit more, but ended up working out that this has been hit in the front and the bumper was pushed back a bit. loosened off the bumper bolts and pushed it forward to give some room for it.
i found using some pliers to bend the edges of the steel where the pipes squeeze past gave more room and a softer spot for the pipe to rub up against ie not have a sharp edge to wear a hole through the pipe.
engine intake is 2.5", cold pipe is 2.25" but box didn't have an adapter. not sure whats gone wrong there. fortunately i had a spare.
mod'ing the washer bottle was a bit of a bust. the plastic is so brittle that it just fell to bits. got something jury rigged. if thats a problem later may have to make a new one.
just looking at it, i recon a 2.5" cold pipe would be better. however would require some extra bending to clear the intake hose and squish the pipe where it goes past the radiator.
fitted a "boost tester" and pressurized the intake. well tried to.
all the air leaked into the exhaust and got no pressure build up.
caped the exhaust found a few exhaust leaks and one on the egr pipe. so thats going to have to come off (or get blocked off).
temp blocked off the egr and got pressure to build up. no leaks or pipes pop'ing off.
however that also means the egr valve is open. afaik it should have been shut at engine shutoff. so i may have to take that out and see why its open.
unfortunately i will not be able to test it with stock tuning, as ecu is away being done at the mo.
its been a little interesting. we had some issues with bumper clearances. i slotted the mounts a bit more, but ended up working out that this has been hit in the front and the bumper was pushed back a bit. loosened off the bumper bolts and pushed it forward to give some room for it.
i found using some pliers to bend the edges of the steel where the pipes squeeze past gave more room and a softer spot for the pipe to rub up against ie not have a sharp edge to wear a hole through the pipe.
engine intake is 2.5", cold pipe is 2.25" but box didn't have an adapter. not sure whats gone wrong there. fortunately i had a spare.
mod'ing the washer bottle was a bit of a bust. the plastic is so brittle that it just fell to bits. got something jury rigged. if thats a problem later may have to make a new one.
just looking at it, i recon a 2.5" cold pipe would be better. however would require some extra bending to clear the intake hose and squish the pipe where it goes past the radiator.
fitted a "boost tester" and pressurized the intake. well tried to.
all the air leaked into the exhaust and got no pressure build up.
caped the exhaust found a few exhaust leaks and one on the egr pipe. so thats going to have to come off (or get blocked off).
temp blocked off the egr and got pressure to build up. no leaks or pipes pop'ing off.
however that also means the egr valve is open. afaik it should have been shut at engine shutoff. so i may have to take that out and see why its open.
unfortunately i will not be able to test it with stock tuning, as ecu is away being done at the mo.