Evolution Racewerks (ER) intercooler install pictures and notes

[Godfather | Jay]

This is by no means a complete write-up, but I collected a bunch of pics from a past ER install and the ER website as well as my own. Hopefully these will help future DIY attempts. Thanks Drew (BlkBullitt) for the pics and help!!

Give yourself plenty of time (ignore the time estimated on the instructions).

Somewhat odd tool notes:
* plug-in die grinder and metal cut-off wheel
* big Torx attachments. 45mm or 47mm or 50mm I don't remember
* nuts and bolts - the new brackets don't come with nuts and bolts *sigh*

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My install pics:

Note: I went from RS4 to ER intercoolers. If your RS4s use an RS4 hard pipe, make sure to get the stock one (thanks Prince at VAST!)

This was pre die grinder... Safety first!! Note: this may not have needed to be cut per the ER picture further down... oh well it was already mangled from the RS4s. Weight savings FTW


Illustrates some plastic cutting done on the inside edge (pics further down show it better):


Action shot. I wish I had pics of cutting with the die grinder. It was like a 4 alarm fire compared to the sparks from the dremel!


Picture to illustrate one of the bigger cuts and a reminder about the bolts. Ignore the RS4 ICs, etc as this is an old picture.


Driver side bolted in. Stock IC bracket was removed (drill out rivets). Horn was remounted behind the IC using the bracket and a purchased nut and bolt.


Passenger side bolted in. Again we removed the stock IC bracket. The AC cannister was remounted using the supplied bracket and some purchased nuts to fit it (the posts). Note that there was nowhere to actually mount this bracket that connected to the A/C cannister. So we chose to zip tie the bracket around a support (it was hollow so no way to drill and use a nut and bolt). We could have drilled a small hole and used a pop rivet... Had to use washers to space the fog light out to keep the back of it from touching the IC.


Quick IAT comparison



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PlanetS4's pics with some add'l notes while being installed at WMS - full thread

Note: Went from AWE to ER

AC hose clearance. Another caveat, by jacking up the passenger side of the car and putting the nose into a semi-service position you can slip the IC in and out with ease from underneath rather than trying to muscle it in from the side. (IIRC we found it easier to come in from the top - using the "chair mod" or having someone pull the front out farther)


These markings were from the AWE trim spec


Trimming of AC bracket for pass side. (we removed entirely)


additional driver side trimming


Slight trimming of bumper plate on passenger side only. (similar to what I did, but I trimmed the lip all the way up)


(Note the missing bumper support bolts. I had one less on the driver side IIRC.)



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Evolution Racewerks pics (a writeup would be nice!)

Didn't have to cut much somehow. ???


No clue how the lower left bolt spot didn't have to be cut off. Please note that you can't install the lower left bolt even if you don't have to cut it off so you may as well cut it off. Same goes for the driver side bolt, but you don't need to cut there.


Note missing bolt again.


Correct pipe connection.

[my2000apb MEGABOOST]

[OldSkewS4]

[Steve_Ag Arrow]

[Godfather | Jay]

[TS4F]

What will that mean in terms of hp, torque, or whatever?

</noob>

[S4lorn]

[Godfather | Jay]

don't know what it will mean in HP/TQ.

I can't wait to do some multi-gear tests to see if they remain as efficient.

[Nigel (no more S4)]

Everyone has has awesome logs of IAT delta throughout the winter months, but now lets see how they perform in 80+ deg ambients

[DVS27t]