The pics below aren't of the one I installed because I forgot to take pics of it but it will give you the idea. That one is actually going for sale on Ebay for a buy it now of $60 so they are going pretty cheap and this would be a good cheap "swap" mod.
You can see how it has on top of it a long bracket, two smaller ones on the same side and then on the back bottom there are 3 tabs with the middle one offset a little lower.
Step 1: remove your front bumper, foglights, bottom metal piece off the bumper cover, etc.
HINT: I find it much easier to remove the whole bumper and bumper cover assembly together. there are two 14mm bolts that hold the bumper brackets in to the frame rails under the vehicle. once those bolts are out, remove all the clips that hold the plastic shroud behind the bumper cover around the radiator, then remove the two 10mm bolts that hold the sides of the bumper in, the marker lights and the whole thing should slide out DONT DROP IT (IMG:
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Step2:
remove the plastic clips that hole the bumper to the bumper cover and pull them apart
Step3: (require tools, reciprocating saw and a wood blade) (IMG:
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**Be careful in this step because when cutting the bumper it will start to melt so turn the speed down on your blade and don't get burned by the melting plastic. Also, you don't want to pull too hard with your saw because the blade will over heat and dull.**
The bumper has 3 sides to it and is shaped like a U. remove the bottom part only up to the brackets so that it now looks like an L in the middle.
Step 4:
Bend the long bracket on the intercooler down about 3.5 inches and then pull the end part back so that it's parallel to the face of the core.
Step 5:
remove some material off the top part of the opening on your bumper cover. Also, remove some of the bottom part of the opening so the core will fit behind it.
Step 6:
place the bumper back into the bumper cover and then lay your core on top of it so that the long bracket touches the bumper. once it's centered in the middle of the opening on the bumper mark where the hole is on that bracket to the bumper. then drill a hole for a bolt to mount the bracket here.
Step7:
bolt the core to the bumper using that hole and the bracket
Step8: put the bumper and bumper cover back together the core should fit nicely but not stable at this point because it's only held in by the long bracket.
Step 9:
install the entire assembly and it should look like the pics above. I haven't plumbed it yet but you get the idea. once the pipes are put on the core will stabilize and you can add extra support using the 3 tabs on the bottom of the core to the radiator support on the vehicle.
Hope you can visualize all that. I will try to get some more pics to help out
How To Install An Evo Viii Intercooler On Your 2g
Oct 15 2008, 06:17 PM
