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Discussion Starter · #1 ·
My son installed my EC intercooler today with the assistance of my 4 year old granddaughter and myself. The removal went as expected. By the time I had printed the 38 pages of XRs excellent instructions, Phillip had already removed the OEM system. We were amazed at the amount of residual oil in the the runners. We were also amazed at how the OEM system was constructed. The rubberish tubes were very thin and looked to be a possible source of future boost leaks.The installation of the new system proved to be a bout of frustration. The first step was the installation of the upper intercooler bracket. None of the holes aligned. Measure and re-drill holes. Next step install hex bolts and washers to the top mounting holes. The bolts didn't fit. Re-tap the holes with M8x 1.25mm tap. Now everything is going forward. Intercooler installed, driver side boost tube installed, passenger side boost tube installed. Oops!!! The hose barb for the boost vacuum line is the wrong size. A new hose was not included in the kit. Time for fabrication. I flush cut the original hose barb from the OEM runner. I then cut the barb tip from the included hose barb. I sanded the EC hose barb until it fit into the OEM hose barb. I cemented the two together with ABS cement. The fabricated adapter works perfectly with the OEM hose and will connect to the EC hose harness for the V4 intake. Waiting for the return of my ECU from EC for a test drive. Guys/Gals this is a really good and recommended upgrade. You won't understand until you feel the difference in quality between OEM and EC product. I don't have stock in EC, but know quality, when I see it.
 

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I'll look into all of this on Monday. A lot of this is really strange, including the bracket holes. I'll have to figure out if the wrong bracket was send out.

Greg
 

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There will be quite a bit of oil in the system.

As for the hose from the EC cold pipe to the intake, I think we are meant to run a silicone hose, not the OEM hose with the clip connectors. I’d be concerned with your solution holding at 26 psi.
 
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There will be quite a bit of oil in the system.

As for the hose from the EC cold pipe to the intake, I think we are meant to run a silicone hose, not the OEM hose with the clip connectors. I’d be concerned with your solution holding at 26 psi.
Shark has a really good point here. I totally missed this before. I don't think we sent the wrong size fitting. I think what's wrong is that we didn't include the hose to connect the intercooler piping to the "T". The system is set up for the V2 or V4 intake, thus you run a silicone line from the intercooler hose to the "T" normally used with the intake. If you are using the stock intake, which isn't something I would normally forsee with this product, you would have to splice the stock hose into the included hose.

Also, please take a look at the install instructions and tell me which photo shows the holes that were not in the right spot. I am looking at this right now, and they seem right at this end. Link:

http://www.124spider.org/forum/361-...w-install-eurocompulsion-intercooler-kit.html

In any case, I'll get all this straightened out on Monday.

Greg
 

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Discussion Starter · #5 ·
I have a V4 intake. I am in the process of pressure testing my adapter. More to come later. Either kaboom or success. I hope the later. I thought that the hose might be missing so I matched up the hose from the V4 boost vacuum line and it only fit on the shoulder of the hose barb. The inside diameter was too large to seat on the barb. I wasn’t too hot on seating it only on the shoulder of the barb. One advantage of my adapter is that in 2023, CA Smog Check, I can put the OEM air intake back without changing back the intercooler. That is the same reason for purchasing the clone tune. What I really like about this group is they really look out for you. Sharks point on my adapter was well taken. Thanks, Shark. That is why I’m doing the pressure test. I’m going to test at 30 psi. I hope that will be enough safety margin. Your thought, please. Also to clarify my previous post on this topic. The holes on the top bracket were off enough that the bolt heads, spacers, and nuts would not sit flat on the mating surface. Drilling was needed to elongate the holes. The mounting bungs on top of the intercooler could have been mistapped at EC’s supplier. It was just the top 2. The bottom was fine. A M8x 1.25 mm tap fixed it.
 

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Discussion Starter · #6 ·
Also noted by my son on removal of the OEM boost tubes was oil seepage at a couple of joints on the turbo side. He said that was an indication of boost leak. With only 4 connections with the EC set up, that issue is history.
 

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Also noted by my son on removal of the OEM boost tubes was oil seepage at a couple of joints on the turbo side. He said that was an indication of boost leak. With only 4 connections with the EC set up, that issue is history.
It sounds like your son is really sharp. Most people would not have noticed that. As the car ages those stock connections do leak, and it's a pain to fix it when they do. We know about this because the 500 Abarth uses a similar set up for the connection points. That's the main reason we made each side one continuous pipe.

I'll get that hose out to you, and whatever else we determine you need. I'll also check the intercoolers in stock for the thread pitch on those holes. It's possible that yours were tapped with the wrong tap at the factory. I'll start to watch for that.

Greg
 

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@depotdan - would you call this a two person job or do you think someone could do it on their own? I'm more or less convinced I'm going to do it - just need to decide if I need to enlist help. I imagine mounting the new intercooler might be tricky on your own.
 

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Discussion Starter · #10 ·
@depotdan - would you call this a two person job or do you think someone could do it on their own? I'm more or less convinced I'm going to do it - just need to decide if I need to enlist help. I imagine mounting the new intercooler might be tricky on your own.
One person can do it. It would have taken me longer to do the job than my 33 year old son. Oh the benefits of youth. He was assisted by my 4 year old granddaughter and myself. If you’re working under the car on your back, it’s good to have an assistant to get tools and materials and to remove materials as they come off the car. The intercooler is the heaviest part of the disassembly and installation. Both are easily handled by one person. The new intercooler with installed mounting bolts and washers will hang from the top mounting bracket as it is tightened. Review XR’s instructions. For me they were very helpful in understanding the overall disassembly and installation. My son didn’t use them, but he has replaced turbos and intercoolers on other cars. Hopefully this helps you. We found the OEM system to be overly complex with many points of potential failure. The EC upgrade is an excellent replacement system. It should be trouble free for the life of the car.
 

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OK, I was all over this issue today with Jordan and Toby. Here is what we found.

The drop down menu when you order this has a spot for the stock intake/V1, OR V2/V4. Somehow that menu was inactive weeks and we didn't notice it. It wasn't working when Dan ordered. We should have caught it earlier, but in any case it's fixed now. It's important to specify what intake you have as the stuff you get will be different. In Dan's case, we sent the wrong stuff and he didn't get a critical hose. One other person is missing that hose as well (Shelby) and it's being sent out.

We checked all the brackets. The ones we have here are from the same batch as Dan's. In fact, they are from the only batch. Extreme's are the same as well. I can't figure out what went wrong here, and I would need pictures to figure it out. The brackets we have in stock fit the intercooler, and the car. Either that one set was off, or Dan put them on upside down or backwards. It would be easy to do when working under the car, and I have certainly made bigger mistakes myself.

Some of the holes tapped in the intercooler's mounts are not that great. I know because we tried to put the bolts in them by hand, and they don't go as smoothly as they should. I didn't find any with the wrong threads, but I did find some that were not tapped that well. We will check all of those from now on by hand threading the bolts into the holes before they go out.

I figured you guys deserved an update on this.

Greg
 

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Thanks Greg. I'll check my intercooler kit tonight for anything that looks out of order. I'm pretty sure I received the cold side pipe evap hose.
 
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Greg,

I've been on a lot of internet forums from hondas to toyotas and now 124 spiders. I haven't yet had the pleasure to witness such great levels of communication and service from any other vendors as you guys at EC. I would like to sincerely thank you for your continued service in a small niche market such as ours. I really appreciate it!
 

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Discussion Starter · #14 ·
I figured you guys deserved an update on this.

Greg
Greg.....as I mentioned in a prior post commitment to your clientele is key to success in any business. Your not ignoring my problem, but accepting it as not trivial reinforces what I have assumed for some time. You care. Your company will be my go to source from now on, because of your commitment to me, a "lowly" consumer. To others I'm just a $ to their bottom line, but you go out of your way to ensure the product you advertise is the product we get. I've been a product and services specialist with The Home Depot for over 30 years. I'm not happy until my customer is happy. That is the feeling I get with your company. I'm off my soap box now. When will Santa be bringing Phase 2?
 

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Discussion Starter · #15 ·
I’d be concerned with your solution holding at 26 psi.
Shark....thank you for your concern with my fabricated adapter. After reading your post I went to my test table. I put my fitting under 30 psi for 12 hours. The fitting held. I thought everything was good until I disassemble my test rig. The hose on the OEM barb was stuck. When I went to twist it off, the fabricated adapter came apart. Apparently my 20+ year old ABS cement wasn't up to the challenge. The cement was pushed to the bottom of the joint leaving no cement on the shaft. Only the bottom edge bonded to the shoulder of the EC hose barb. When I twisted it, the bond broke. Gotta learn not to be such a pack rat. Back to the drawing board. I used Plastruct to reassemble my adapter. It's a solvent used for Polystyrene, ABS, and acrylic plastics. I brushed on the cement, assembled the adapter and allowed it to cure for 24 hours. My son recommended testing at twice max operating pressure. I put the test assembly in my safe drawer and turned the pressure up to 65 psi. I listened for a pop and heard none. I let the assembly sit under pressure for four hours. It held. I depressurized the system and removed my adapter. This time it did not twist apart. I am confident in its ability to withstand the pressure exerted by the 124 turbo system. EC uses the OEM hose for their V4 system. I will be using it in my application using the V4 intake. My car, my responsibility. I'm sure it will work well and when my annual CA Smog Check comes due in 2023, I can put back my original air cleaner and be CARB compliant. Thanks again. Without your post I would have had a failure with drivability issues.
 

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Shark....thank you for your concern with my fabricated adapter. After reading your post I went to my test table. I put my fitting under 30 psi for 12 hours. The fitting held. I thought everything was good until I disassemble my test rig. The hose on the OEM barb was stuck. When I went to twist it off, the fabricated adapter came apart. Apparently my 20+ year old ABS cement wasn't up to the challenge. The cement was pushed to the bottom of the joint leaving no cement on the shaft. Only the bottom edge bonded to the shoulder of the EC hose barb. When I twisted it, the bond broke. Gotta learn not to be such a pack rat. Back to the drawing board. I used Plastruct to reassemble my adapter. It's a solvent used for Polystyrene, ABS, and acrylic plastics. I brushed on the cement, assembled the adapter and allowed it to cure for 24 hours. My son recommended testing at twice max operating pressure. I put the test assembly in my safe drawer and turned the pressure up to 65 psi. I listened for a pop and heard none. I let the assembly sit under pressure for four hours. It held. I depressurized the system and removed my adapter. This time it did not twist apart. I am confident in its ability to withstand the pressure exerted by the 124 turbo system. EC uses the OEM hose for their V4 system. I will be using it in my application using the V4 intake. My car, my responsibility. I'm sure it will work well and when my annual CA Smog Check comes due in 2023, I can put back my original air cleaner and be CARB compliant. Thanks again. Without your post I would have had a failure with drivability issues.
That is awesome! :)
 

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OK, I was all over this issue today with Jordan and Toby.

We checked all the brackets. The ones we have here are from the same batch as Dan's. In fact, they are from the only batch. Extreme's are the same as well. I can't figure out what went wrong here, and I would need pictures to figure it out. The brackets we have in stock fit the intercooler, and the car. Either that one set was off, or Dan put them on upside down or backwards. It would be easy to do when working under the car, and I have certainly made bigger mistakes myself.

Some of the holes tapped in the intercooler's mounts are not that great. I know because we tried to put the bolts in them by hand, and they don't go as smoothly as they should. I didn't find any with the wrong threads, but I did find some that were not tapped that well. We will check all of those from now on by hand threading the bolts into the holes before they go out.

I figured you guys deserved an update on this.

Greg
Greg,
The bracket was installed correctly but when I was installing the bolts the 2 in the center were about 3/16” off so I redrilled them so they were inline with the factory holes. It probably would have been fine if I just tightened them up but my OCD wouldn’t let me. I also drilled a 4th hole to utilize the horn mount as well (Relocated the horn all together) I liked that the outer 2 factory holes had nuts welded on. Over all the kit is very well setup an I would recommend it to everyone as a factory style upgrade to eliminate the factory slip connections that were already leaking on depotdan’s car.
Happy Motoring!
 
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