How to Install EUROCOMPULSION Intercooler Kit

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XtremeRevolution

Discussion Starter · Sep 17, 2017 (Edited)

6

How To Install EUROCOMPULSION Intercooler Kit

Overview:
To learn more about the intercooler, check out these two threads:
- Stock vs EC Intercooler: https://www.124spider.org/forum/10-...090-stock-vs-eurocompulsion-intercoolers.html
- More info on the EC Intercooler: https://www.124spider.org/forum/45-...ooler-kit-eurocompulsion-official-thread.html

Depending on your level of preparation and whether or not you have an assistant, expect this to take you anywhere from 4 to 11 hours to complete. This tutorial is divided into 8 parts, split across page 1 of this thread.

Tools Required:
- 7mm & 8mm 1/4 drive sockets or 1/4 drive bits
- Mini ratchet driver (Like this one on Amazon.com)
- 3/8" drive ratchet with 10mm socket
- 10mm, 12mm, 13mm, and 14mm offset wrenches
- Flathead screwdriver
- Long flathead screwdriver
- 21mm socket (for lugnuts)
- 5mm and 6mm hex bits (a multi-bit hex tool will also work)
- A jack, two jack stands, and a jack pad. (I got mine on Amazon.com)
- Soapy water

Note: The mini ratchet driver will make your life a lot easier. You'll be working in some tight spaces, so small and maneuverable tools will be good to have.
Note: If you don't have access to a lift, you'll be under the car on your back for a couple of hours. I recommend a helper to pass you tools so you don't have to keep crawling back out, and a stiff pillow (or blanket you can roll up) you don't mind getting dirty to make this more comfortable. This tutorial assumes you do not have access to a lift.

Part Required:
EUROCOMPULSION FIAT 124 Spider Intercooler Kit

Part 1: Stock System Overview:
Before you start, it will be helpful to familiarize yourself with the stock system. I put it mostly together in the image below:

Marked with red arrows are connections fitted with hose clamps. There are 5 hose clamps total. Some use 7mm and some use 10mm bits/sockets.

Marked with yellow arrows are joints between the flexible rubber hose and the plastic pieces. There are 5 of these joints in total.

To disconnect the hoses from the plastic pieces, I simply wedged a flathead screwdriver under the wire retainer and lifted it out of the locking slot. This is all you need to do to disconnect these; the hose will slide right out.

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XtremeRevolution

Discussion Starter · #2 · Sep 17, 2017 (Edited)

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Part 2: Preparation
1. Lift the front of the car enough that you will be able to comfortably work underneath. As noted above, I recommend using a jack pad to protect the pinch welds.

2. Remove the front wheels on both sides. The lugnuts use a 21mm socket.

3. Remove all of the fasteners holding the upper wheel well liner in place. To do this, simply slide the screwdriver under the center tab and wedge it outward. Note: I'm not marking all of the fasteners since there are simply too many. Work your way around and remove all of them until the liner comes out.

4. Remove the front wheel well liner, working your way underneath the car as well. Note, you will find some metal screws here as well that you can remove either with a socket or with a Philips screwdriver. Do not remove the fasteners marked in red.

5. Repeat steps 3-5 for the passenger side of the car.

6. Remove the center under-body shield. Note that the fasteners on the rear are larger than the ones you pulled earlier. Make note of this for re-assembly. There are also two 10mm bolts in the rear and some screws in the front.

7. Next, move over to the engine bay.

8. Remove the intake. If you have a stock intake, follow steps 1 through 11 in this tutorial: http://www.124spider.org/forum/361-...281-how-install-eurocompulsion-v2-intake.html

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XtremeRevolution

Discussion Starter · #3 · Sep 17, 2017 (Edited)

18

Part 2: Preparation, continued

9. Next, loosen the battery terminals with a 10mm socket (lift the flap on the + side), and remove (or loosen) the two nuts holding down the battery bracket. Note: once you remove the battery, you will have no power in the car. This means you won't be opening the trunk or sliding up the windows. If you're parked outside, make sure the car is unlocked, top up, and the windows up before you pull the battery.

10. Remove the battery sleeve by pulling upward.

11. Remove the battery.

12. Remove the three bolts holding down the battery tray.

13. Using a fastener removal tool or flathead screwdriver, remove the fastener marked below.

14. Next, remove the wiring harness from the battery tray. To do this, you have to rotate the battery tray and wiring until the fastener and tray line up.

15. Remove the battery tray.

You're now ready to remove the stock intercooler hoses.

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XtremeRevolution

Discussion Starter · #4 · Sep 17, 2017 (Edited)

18

Part 3 - Driver's Side Removal

1. Loosen the hose clamp going into the intercooler elbow, and disconnect the other end of the hose from the plastic piece.

2. Loosen the hose clamp going into the turbo (from the top of the engine bay), using a 10mm socket.

3. Disconnect the diverter valve wiring.

4. From the wheel well, remove the plastic shield held on by the bolts marked below.

5. Remove the bolts that go in the positions marked in red. I didn't get a chance to take a picture of these before removal. Next, remove the nuts securing the sway bar to the chassis. Do this for the passenger side as well.

6. In the engine bay, you'll see the following bolt holding a bracket to the chassis. Remove it using a wrench. This bolt holds down the bracket for the plastic hose piece. You can also remove this with some extensions and a swivel from the engine bay.

7. Remove the hose from the turbo, and disconnect the other end of the hose from the plastic hose piece.

8. Back down in the engine bay, you'll now be able to move the plastic intake piece. Move it rearward so you can access the bolt holding the bracket to the plastic piece. Remove this bolt.

9. By moving the sway bar forward, you will now be able to slide the plastic piece out from underneath the car, completing the removal of the driver side intercooler hose.

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XtremeRevolution

Discussion Starter · #5 · Sep 17, 2017 (Edited)

21

Part 4 - Passenger Side Removal

1. Loosen the hose clamp connecting the rubber hose to the elbow coming out of the intercooler.

2. Disconnect the other end of the rubber hose, and remove from the car.

3. From the passenger wheel well, remove the plastic shield. This shield is held on by one fastener, and a clip molded into the shield itself (bottom arrow). To fully remove it, just pull sideways. Next, remove the two bolts shown and separate the brake line bracket.

4. Remove engine shield by removing the 12mm bolts marked below.

5. Disconnect the retaining clip on the hose as shown below.

6. At the other end of the hose, disconnect the retaining clip, and remove the hose from the car. Next, remove the two bolts marked in red.

7. Look up into the engine bay from the opening to the passenger side of the engine, and you'll see two hose clamp heads. Loosen both of these, with a 7mm and 10mm socket/bit respectively.

8. Attached to this plastic intake piece is a sensor with a clip just like the one attached to the diverter valve in Part 3 - Step 2. I found it easiest to use a long screwdriver to wedge the yellow locking clip outward, then disconnect the wiring from underneath the car.

9. To get this plastic intake piece out of the car, rotate it clockwise until the upper bolt bracket clears the engine mount, and pull toward you from the bottom.

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XtremeRevolution

Discussion Starter · #6 · Sep 17, 2017

8

Part 4 - Passenger Side Removal, continued

10. From underneath the car, use a 10mm wrench to remove the two bolts (which you cannot see) holding the metal bracket that holds the plastic piece that's still in the car. This is easier than it looks, just take your time.

11. Once you have the bracket disconnected, you can rotate the plastic piece. On the top, disconnect the hose by sliding the purple locking clip backward. The hose can then be removed through the top of the engine bay.

12. The final plastic piece can be removed in the following alignment to the passenger side of the engine.

13. Using the 6mm hex bit, remove the sensor from the plastic intake piece as shown below.

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XtremeRevolution

Discussion Starter · #7 · Sep 17, 2017

8

Part 5 - Intercooler Removal

1. Disconnect the 3 nuts on each end of the intercooler to remove the elbows.

2. Remove the nut shown below on both sides of the car.

3. Above the intercooler, remove the bolt shown below on both sides of the car.

4. On the passenger side, you may have another bracket attached to the intercooler bracket; remove the nut holding this one on.

You should now be able to remove the intercooler from the car in addition to the two brackets.

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XtremeRevolution

Discussion Starter · #8 · Sep 17, 2017 (Edited)

12

Part 6 - EC Intercooler Install

1. There are two bolts holding the front horn in place. First, remove the lower bolt and disconnect the horn entirely. Bend that end of the bracket forward, or it will not clear the intercooler. Reinstall the horn, and re-position the bracket as needed by loosening the bolt marked at the top if needed.

2. Install the top bracket using the three bolts, three nylon spacers, and two nuts in the alignment shown below.

3. There should be two bolts on top of the intercooler. Loosen those so you have a good 1/2" or so of clearance, then fit the intercooler over the slotted opening. It helps to have a helping hand for this step.

4. You should have some washers with the upper intercooler bolts. Since the washers will be at the bottom when you hang the intercooler, disconnect one side at a time, moving the washers to the top, and re-hang the intercooler on the bracket so that the washer is above the bracket, not below. Next, tighten the bolts from underneath the car using a wrench.

5. Install the lower bracket by reusing the bolt attached to the chassis, and one of the nuts you removed from the OE brackets. Additionally, install the lower bolts using the 7mm hex bit.

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XtremeRevolution

Discussion Starter · #9 · Sep 17, 2017 (Edited)

17

Part 7 - EC Intercooler Hose Install

After fighting with the OE intercooler plumbing, you'll laugh at how easy this part is. I got the driver's side installed in under 5 minutes.

1. Coat the inside of the intercooler hose with soapy water, on both ends. This will make reinstall much easier.

2. Run the driver side intercooler hose through, underneath the sway bar, and into the engine bay. Attach the bottom end to the intercooler.

3. Attach the other end of the driver side hose to the turbo, and tighten the clamp.

4. Run the passenger side intercooler hose through. You may need to do some twisting and rotating of the hose, but follow the original path and it will fit pretty easily.

5. Attach the lower end of the hose and tighten the hose clamp.

6. Attach the upper end of the hose to the throttle body, and tighten the hose clamp securely. I didn't get a picture of this, but I found that aligning the hose clamp head to the left (as you sort of see in this next photo) was an easy way to install it. Make sure it's pushed all the way up and snug, and make sure it's tight, since it's under high pressure and you don't want it popping off. Next, install that sensor you removed earlier. This will be a bit of a tighter fit. Attach the wiring connector and push in the locking clip. Note: I've learned that there should be a hose clamp here. While not pictured, it will be included in your intercooler kit.

7. Lastly, attach the vacuum hose and run it back up into the engine bay. Note the orientation of the hose clamp here. You may need to rotate this so it is facing away from the A/C line. This ensures that it will not rub against the A/C line. In my car, I found that I had to bend the A/C line half an inch or so away from the intercooler hose as it was too close for comfort.

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XtremeRevolution

Discussion Starter · #10 · Sep 17, 2017 (Edited)

Part 8 - Final Steps

1. Reinstall the brake line bracket.

2. Reinstall the plastic shield next to the brake line bracket.

3. Reinstall the plastic shield on the driver side to the left of the sway bar bushing.

4. Reinstall the sway bar bushing nuts.

5. Reinstall the lower body panel, the engine shield, and the wheel well liners.

6. Reinstall the battery tray, reconnect the wiring, and reinstall the battery.

7. Reinstall the diverter valve wiring connector.

8. Reinstall the intake (remember to connect the black vacuum hose coming out of the passenger side intercooler hose).

9. Reinstall the wheels, torque lugnuts to 80 lb-ft (can someone double check this?) and lower the car.

10. Go out for a drive.

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XtremeRevolution

Discussion Starter · #11 · Sep 17, 2017

Thread has been re-opened. If anyone has any questions, contributions, or corrections to make, please let me know.

68wooley

· #12 · Sep 18, 2017

Great job again XR. Doesn't seem too intimidating.

klikai

· #13 · Sep 18, 2017

Holy..

This looks long...

How long did it took you? How long do you think a good mechanic will take with the instruction manuals?

....Just trying to figure out how much it would cost me for labours

Greg

· #14 · Sep 18, 2017

Xtreme: Your install looks great, and your instructions are fantastic. The only think I wish to add is that you should have a clamp for the boost sensor that's located in the intercooler pipe just upstream of the throttle. If one wasn't included, either source one locally, or I'll send one out to you. I'll double check and make sure those are in the kits and send them to anyone who has already bought one.

Greg

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Greg

· #15 · Sep 18, 2017

klikai said:
Holy..

This looks long...

How long did it took you? How long do you think a good mechanic will take with the instruction manuals?

....Just trying to figure out how much it would cost me for labours

I am sure Xtreme will answer this, but I think that 4 hours would be a safe number. It's very possible that an experienced person will do it in 3, and if you have done it before, it could even get down to 2 hours. Most of the time is spend in removing the factory parts. Ours are actually much easier to install.

Greg

klikai

· #16 · Sep 18, 2017

Greg said:
I am sure Xtreme will answer this, but I think that 4 hours would be a safe number. It's very possible that an experienced person will do it in 3, and if you have done it before, it could even get down to 2 hours. Most of the time is spend in removing the factory parts. Ours are actually much easier to install.

Greg

I see, thank you Greg

Greg

· #17 · Sep 18, 2017

Update:

The clamps for the boost sensor are in all the kits that have been sent out, so that's not an issue.

In regards to silicone spray to lube up the pipes, our official recommendation is to use only a mixture of dish soap and water. The problem is that with so many types of "silicone" spray out there, and so many different propellants in aerosol cans, there is no way we can be sure which sprays may or may not be harmful to the silicone itself. Just use dish soap and water. You probably already have it, it's cheap, works well, and is harmless.

Greg

P.S. Xtreme's instructions are so good that we are probably going to make those the official instructions. We really can't do any better.

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XtremeRevolution

Discussion Starter · #18 · Sep 18, 2017

klikai said:
Holy..

This looks long...

How long did it took you? How long do you think a good mechanic will take with the instruction manuals?

....Just trying to figure out how much it would cost me for labours

Hard to tell. I had to run out to the store a couple of times for tools I didn't have (like a 21mm socket), and spent a great deal of time fighting with the plastic pieces until I figured out the best way to get them out. Also spent a lot of time taking photos. I probably took 3 photos of each part since with my luck, two of them would turn out blurry. It's definitely a longer job, but not really a difficult one. Give yourself 4 hours from start to finish. If you have all of the tools needed, you'll be fine.

Greg said:
Xtreme: Your install looks great, and your instructions are fantastic. The only think I wish to add is that you should have a clamp for the boost sensor that's located in the intercooler pipe just upstream of the throttle. If one wasn't included, either source one locally, or I'll send one out to you. I'll double check and make sure those are in the kits and send them to anyone who has already bought one.

Greg

Mine didn't come with a clamp, but I'll pick one up locally soon. It was a pretty tight fit, so I wasn't too worried about it, but I'll get one on there for good measure.

Greg said:
Update:

The clamps for the boost sensor are in all the kits that have been sent out, so that's not an issue.

In regards to silicone spray to lube up the pipes, our official recommendation is to use only a mixture of dish soap and water. The problem is that with so many types of "silicone" spray out there, and so many different propellants in aerosol cans, there is no way we can be sure which sprays may or may not be harmful to the silicone itself. Just use dish soap and water. You probably already have it, it's cheap, works well, and is harmless.

Greg

P.S. Xtreme's instructions are so good that we are probably going to make those the official instructions. We really can't do any better.

I've updated the instructions to omit silicone spray and recommend soapy water instead. As a side note, my method has always been to spray the silicone spray on a microfiber towel, wait for the carrier to dry a few seconds, then wipe the surface. I generally try to avoid spraying any rubber or silicone parts with silicone spray directly as I've been warned about the propellant/carrier compatibility in the past. I didn't clarify that in my tutorial, but you're right. Everyone has soapy water.

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hefbadr

· #19 · Sep 18, 2017

Thank you for an awesome tutorial. Your dedication and expertise in this forum is beyond compare. Thanks again. Just waiting for funds availability to take the plunge.

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depotdan

· #20 · Sep 18, 2017

Greg said:
Update:

P.S. Xtreme's instructions are so good that we are probably going to make those the official instructions. We really can't do any better.

It would be hard to improve on the pictures and flow of information/instruction given in this tutorial. I feel confident that i will be able to complete the installation with the guidance given. Xcellent job Xtreme and equally excellent job Greg.

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