GReddy Intercooler Installation

I performed this installation as part of a larger project which included an APEXi AVC-R boost controller, J&S Safeguard, GReddy Oil Catch Can, and some gauges. I also installed a SPAL 7½" puller fan as part of the IC upgrade. I can't imagine putting the stock fan on a new intercooler, and I doubt anyone else would, either. I installed a special circuit that would enable this fan to be energized either with ignition power or battery power, or turned off entirely. 

Because of the scope of my project, some of the photos might show more disassembly than is actually required. It's also likely that the photos don't always match EXACTLY what's in the text. As is often the case, I would have changed the sequence of a few things if I had to do it over again. 

I've not listed the torque settings for the various fasteners. I consulted the BGB on most of them, but I've also learned that the BGB has errors, and some of them refer to incorrect torque settings. I'd like to avoid any potential for someone to point their finger at my instructions as the cause of that broken or lost fastener. If I find an incorrect setting that could cause a problem, I'll mention it, but generally you should use your own experience and the BGB as the guide. If you don't have the BGB, get a set.

The materials list is specific to my project. You will likely make some choices different from my own and your list will vary somewhat. I hope I have included most of the tools, etc., required, but my memory is not what it used to be.

While most of this work was performed by myself, I did solicit the help of a friend for removal of the stock intercooler. I was trying to remove it undamaged, and this proved close to impossible for one person without removing the right-hand motor mount. It might be possible, but I took the easier route.

The photos in this guide can be enlarged by clicking on them. This will greatly improve the clarity of the area in question. 

As with most projects, many people deserve credit for providing ideas, plans, and materials. Here are a few of the direct contributors:

Marc Summers for the SPAL fan wiring ideas

Anthony Sarno for his intercooler installation write-up on MR2.com (www.mr2.com/article/greddyic_install.html)

Aaron Bunch for the SPAL fans (www.atsracing.net)

McMaster-Carr, which is an invaluable source of materials and hard-to-find items. They have an expansive selection of parts on their web site (www.mcmaster.com), they'll fill any size order, and they ship the same day 99% of the time.

Finally, remember that this is only a guide -- not gospel. What you do to YOUR vehicle is YOUR responsibility. I do not endorse, approve, authorize, or otherwise encourage you to make alterations to your vehicle. Be careful, and recognize the dangers associated with modifications to your vehicle's critical systems, like electrical, engine, brakes, etc.

Please contact me if you have comments or suggestions about the article or the project, or if you find errors on these pages.
 

Tools & Materials Needed

• 10, 11, 12, 13, & 14mm sockets in a variety of drive sizes.

• A very healthy assortment of socket extensions and adapters. If you've done any work on an MR2, you know that you can never have too many different sizes of extensions.

• 10, 11, 12, 13, & 14mm combination wrenches

• Assorted screwdrivers

• Floor jack and jack stands

• Optional T-Bolt hose clamps (McMaster-Carr)