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Universal intercooler, the guide.

Discussion in 'Ibiza Mk5' started by turboboy, Aug 13, 2013.

  1. turboboy

    turboboy Limp Mode Squad ™

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    Ok guys and girls, welcome to my guide to fit a universal type intercooler to your mk5 cupra,Boc ,fr. My car is a facelift mk5 so there maybe some small differences but nothing major.

    You need

    550x140x65mm intercooler

    2x 90* bends with 57mm internal diameter

    2x 57mm alloy joiners

    4x 60-70 mm hose clips

    And it gives you this, the kit built up (will need trimming etc)

    Right I found there is quite abit more room for a much taller cooler, not sure why the size I bought was recommend but there is soo much more headroom to go much bigger.

    [​IMG]

    All of the above came to £95 and my 50mm-70mm hose clamp came to £7, you need 4 clamps as you can re use 2 original clamps

    So that's the kit and now you need to fit it.

    I taped my car up to protect headlights, bumper etc etc and I suggest you do the same (my cars only done 2k miles)

    Firstly lift the bonnet, there are Slam panel clips x4

    [​IMG]

    Next there are Wheel arch t25 x4 each side

    [​IMG]

    And then X2 t25 under the bumper each side

    [​IMG]

    Pull bumper outwards from arch working your way towards the light each side and it will reveal 1x t25 inner inner arch screw

    [​IMG]

    From here you can undo the fog light connectors
     
    #1 turboboy, Aug 13, 2013
    Last edited: Aug 13, 2013
  2. turboboy

    turboboy Limp Mode Squad ™

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    no picture.

    Pull bumper forward and hear it unclip, all fixing screws should be out but don't go too mad just incase you car is different

    Undo headlight washer feed if you have them and unbolt pas side washer and feed the water supply through and out the way

    [​IMG]

    Remove bumper

    [​IMG]

    Disconnect outside temp sender from its housing and tuck out the way

    [​IMG]

    Remove headlight 5xt30 each head light remove and unclip wiring (these are really hard) there are 5 bolts make sure you get them all, then remove

    Unbolt crash bar 3x 13 and 1x10 each side

    [​IMG]

    Unclip bonnet catch wiring and unclip the loom from slam panel

    [​IMG]

    [​IMG]
     
    #2 turboboy, Aug 13, 2013
    Last edited: Aug 13, 2013
  3. turboboy

    turboboy Limp Mode Squad ™

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    Unclip air box feed

    [​IMG]

    1xt30 each side front brace/slam panel

    [​IMG]

    Unbolt bonnet latch 2xt30, unclip bonnet catch loom and release cable from slam panel,lift catch out and feel both loom and release cable toward the catch to allow you to pull it up to work on it. Remove bonnet cable from catch and unfeed out of slam panel and put it out the way, re locate bonnet catch.

    [​IMG]

    [​IMG]

    [​IMG]

    Rescuer your bonnet, your bonnet stay in attached to your slam panel and we are going be removing it from the car shortly

    We are now removing the frame, undo the top 10mm bolts 1 each side and tilt the frame forward, this will detach the condenser and rad from the top part of the frame. Now pull the rad up and push downwards on the frame, this will un locate the locating pin/clips at the bottom and remove frame

    [​IMG]
     
  4. turboboy

    turboboy Limp Mode Squad ™

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    Undo hose clips (you can reuse these) and detach from intercooler. To remove the Intercooler on the pas side there is a clip on the front and back that need leavening out and pushing down, the intercooler sides out on the drivers side.

    [​IMG]

    [​IMG]

    Your need something to prop the rads up.

    [​IMG]

    We are now going to fit the intercooler .

    I decided I wanted to fit the intercooler as far away from the rad as possible so I cut the top section of the intercooler cradle away, you will see this allows you to bring the intercooler forward and will show the intercooler more.

    [​IMG]

    Cut this


    [​IMG]

    So it's like this

    [​IMG]
     
  5. turboboy

    turboboy Limp Mode Squad ™

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    Next we marked up the cradle and bolted the intercooler to it, I used spacers to lift the intercooler and allow the bottom intercooler fins to get air flow.

    [​IMG]

    [​IMG]

    Refit the front frame to the car and re locate the rad, make sure everything lives back where it used to and fits correctly then refit the 2x top 10mm bolts and put your bonnet stay back up

    [​IMG]

    [​IMG]

    Remove the horn 1x13mm bolt so you have room to cut away the intercooler cradle

    [​IMG]

    We now need to cut quite abit away to run the new intercooler pipes

    Here is pas side pics

    [​IMG]

    [​IMG]

    The end connecting to the intercooler needs triming down (trial and error with it)

    On the drivers side both ends of the 90 pipe needed trimming and I found reversing the standard intercooler pipe so it look like this makes a neater and straighter run

    [​IMG]

    [​IMG]


    Cut away the intercooler cradle

    [​IMG]

    Fit pipes like this (trim both ends of 90* pipe

    [​IMG]

    [​IMG]

    Make sure all your pipes are tight and put the thing back together in reverse of the dismantle.

    [​IMG]

    Hope this helps

    Please if your selling these kits do not use my text or images.
     
    Big-Pete likes this.
  6. Big-Pete

    Big-Pete Always on the Limit

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    how much space is there between the crash bar and the intercooler width wise? i might get a taller fmic and cut the bar about a bit.

    great guide :)
     
  7. Big-Pete

    Big-Pete Always on the Limit

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    also ebay links wont work dude.
     
  8. turboboy

    turboboy Limp Mode Squad ™

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    Hmmm,Links were working off my notes last night

    Enough room to go upwards and clear the crash bar or very very little triming.
     
  9. Big-Pete

    Big-Pete Always on the Limit

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    hmm, maybe a full size fmic setup. tempting.
     
  10. turboboy

    turboboy Limp Mode Squad ™

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    Ill try and remake a shopping list later
     
  11. turboboy

    turboboy Limp Mode Squad ™

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  12. DEAN0

    DEAN0 Old Git

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  13. turboboy

    turboboy Limp Mode Squad ™

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  14. DEAN0

    DEAN0 Old Git

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    Ah OK i must have read the sizes wrong

    Yours is quoted as 550 long, 140 high and 65 wide

    The one i linked to says its 550 long, 225 high and 64 wide

    I assumed the 140 to 225 difference would be the height
     
  15. turboboy

    turboboy Limp Mode Squad ™

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    Maybe I'm wrong then and got the sizing mixed up. The length has to stay the same but you can go higher
     
    #15 turboboy, Aug 13, 2013
    Last edited: Aug 13, 2013
  16. turboboy

    turboboy Limp Mode Squad ™

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    I've edited the first post as a list of parts you need rather than what I bought as my eBay links are not working.Deano your absolutely correct I mixed myself up with intercooler sizing and that one could possibly fit and its a good price.

    Saying that though my intercooler is working very well, there is a noticeable difference with this fitted, I'm not sure you really need anything bigger tbh.
     
  17. DEAN0

    DEAN0 Old Git

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    I'm going with your size of cooler - looks factory and won't draw any attention.

    I just looked for larger ones when others suggested that bigger MIGHT be better

    Just need to check if my 2.0TDi has the same fittings as yours.
     
    #17 DEAN0, Aug 13, 2013
    Last edited: Aug 13, 2013
  18. turboboy

    turboboy Limp Mode Squad ™

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    Edited due to wrong info
     
  19. Nick G

    Nick G Full Member

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    Just wanted to say well done to Robbie for this guide, I know he's put a lot of time and effort into writing it all up and not just out to make a quick buck like some of the Ebay sellers that will probably now copy his text and re-word it somehow. Shame on you if are reading this guide with that in mind :)

    Robbie popped over to mine last night and let me have a quick blast in the Ibiza and it's an awesome car, the noise is terrific and really pulls well - Fair play modifying a brand new car, I have no idea what they're like standard but this thing really impressed me!
     
  20. turboboy

    turboboy Limp Mode Squad ™

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    So has anyone used the guide yet? Found it helpful? Who else has now fitted this?
     

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