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Intercoolers

05-08 (B7) Audi A4 2.0T Competition Series Front Mount Intercooler (FMIC) Kit PARTS CHECKLIST

05-08 (B7) Audi A4 2.0T (all) Competition FMIC Full Kit

Front Mount Intercooler Assembly x1
Turbo to Intercooler Pipe x1
Lower Intercooler Pipe to Throttle Body Pipe x1
Throttle Body Pipe x1
Silicone Hose Coupler - 1.75" to 2.25" Transition x1
Silicone Hose Coupler - 2.25" Hump x1
Silicone Hose Coupler - 2.50" Hump x1
Silicone Hose Coupler - 2.50" Straight x2
T-Bolt Clamp - 1.75" (200) x1
T-Bolt Clamp - 2.25" (263) x3
T-Bolt Clamp - 2.50" (288) x6
MAP Sensor Hex Bolt (6mmx1.00) 12mm long x2
Power Steering Cooler x1
Power Steering Hose x2
Power Steering Hose Clamps x6
Power Steering Hose Brass Barbed Connector x2
Power Steering Cooler Mounting Strap x4
Power Steering Cooler Mounting Clip x4
Power Steering Cooler Mounting Cushion x4
Zip Ties x2
Documentation x1
Sticker Packet x1

05-08 (B7) Audi A4 2.0T Competition Series Front Mount Intercooler (FMIC) Kit INSTALLATION GUIDE

Tools Needed:

Full set of metric sockets and wrenches.

Philips screwdriver.

Flat head screwdriver.

Full set of Hex sockets and/or wrenches.

Full set of Torx sockets and/or screwdriver bits.

Long Torx T-handle Set

Triple Square (XZN Socket) 10mm

Tool to cut the bumper (dremel, sander, etc…)

Parts Needed:

Audi/VW Power Steering Fluid

Install Time: 4-5 hours.

Difficulty (1 Easy, 5 Hard): 2

Removal

  1. Lift up the car - Jack up the front of the car and put on stands.  ALWAYS PUT THE CAR ON STANDS WHENEVER YOU GO UNDERNEATH IT.  FAILURE TO DO SO MAY RESULT IN INJURY OR DEATH IF THE JACK FAILS.
  2. Remove the side grill/fog light covers - They are held in place by clips. Grab the fog light covers by the edges and gently, but firmly pull forward.
  3. Unbolt the bumper reinforcement bar - Once the side grill/fog light covers are removed, the hex socket bolts holding the bumper reinforcement bar to the bumper reinforcement bar support shock can now be accessed. There is (1)  10mm triple square (XZN socket) bolt holding each side of the bumper reinforcement bar and is located right behind the fog light cover hole, towards the top. 
  4. Remove lower engine guard - The lower engine guard is attached by (9) flat head screwdriver screws.  Remove screws and remove the lower engine guard.
  5. Remove wheel well/fender liner from the front bumper – There are (1) plastic flat head screwdriver screw, (7) T-25 Torx screws, and (1) plastic push pin on each side of the wheel well liner.  Once the wheel well liner is removed, there are (2) T-25 Torx screws holding a bracket to the front bumper.
  6. Remove the front bumper - There are (3) T-30 Torx screws on top of the bumper cover.  One screw is located next to each of the headlights and one in the middle (top) of the bumper cover.  The bumper is also held in place by (4) 10mm nuts (2 on each side) which are located underneath the headlights and behind the fenders (where the fender and front bumper meet).  Remove these nuts and pull the front bumper out of the way.  There  are 2 wiring harness behind the bumper for the fog lights and horns.  Disconnect the connector plugs.  There is also a water hose behind the bumper for the headlight washers.  Put a container underneath the water hose connector to catch the washer fluid.  Disconnect the water hose. 
  7. Remove the bumper reinforcement bar from the front bumper - The bumper reinforcement bar is held onto the bumper cover by (2) pads on top of the bumper reinforcement bar.  Unscrew the pad and remove the bar from the bumper cover.
  8. Remove the headlights - Remove the airbox ducting on top fo the passenger side headlight.  It is held in place by (2) Philips head screws.  Once removed, the headlight is now accesible.  The headlight is held in place by (3) T-30 Torx screws.  Two of the Torx screws on each headlight are easily visible.  Remove them.  There is an access hole for a hidden Torx screw above the headlight, next to the fender.  You will need a long T-30 Torx (t-handle or extension) to reach the hidden Torx screw.  Loosen the screw enough so that the headlight can slide out of the car.  DO NOT REMOVE THE SCREW.  Detach the headlight connector plug from the headlight.
  9. Remove all intercooler hoses (pipes) - There are three total.  Unscrew the worm clamps holding the OEM intercooler hoses and remove all of them from the car.
  10. Disconnect the MAP sensor – The MAP sensor is located on the top end tank of the OEM driver’s side intercooler
  11. Remove both OEM intercoolers - Remove both factory intercooler shrouds.  On the bottom of the driver's side OEM intercooler, there is (1) T-30 Torx screw holding the air conditioning line to the intercooler which needs to be removed.  Pull the bottom of the OEM intercooler towards the front of the car which will release the lower mount from the rubber grommet on the intercooler bracket.  Lift the OEM intercooler upwards which will release the upper mounts off the rubber grommets on the intercooler bracket.  The OEM intercooler should now be free of the the bracket.  Remove from the car.  Repeat on the other side.
  12. Remove both OEM intercooler brackets - The passenger side intercooler bracket is held in place by (3) 10mm bolts.  The driver side intercooler bracket is held in place by (2) hex socket bolts in the front and (1) 10mm bolt behind the windshield washer fluid reservoir.  Use an extension and go through the wheel well to reach and remove the 10mm bolt.
  13. Remove the MAP sensor from the stock intercooler - The MAP sensor is held in place by (2) Torx screws.  Unscrew them and carefully pull out the MAP sensor.  THE MAP SENSOR HAS A GREEN RUBBER O-RING THAT SEALS IT.  BE CAREFUL NOT TO DAMAGE IT WHEN REMOVING.  INSPECT THE GREEN O-RING FOR DAMAGE BEFORE REINSTALLATION.
  14. Remove the plastic shrouding surrounding the radiator/air conditioning condenser - You can trim the plastic shrouds so that it will fit with the FMIC if you want to retain them.
  15. OPTIONAL - If you do not have VAG power steering fluid or if you want to use the OEM power steering line instead of the included external power steerin cooler, SKIP REMOVAL STEP 16 AND INSTALLATION STEP 3.  You will need to bend the OEM power steering line upwards towards the side of the intercooler.  MAKE SURE YOU DO NOT KINK OR BREAK THE LINE.
  16. Remove the OEM power steering hard line - Unclip the sensor attached to the OEM power steering hard line (located in front of the car).  Remove the OEM power steering hard line from the stock rubber line (have a bucket underneath as power steering fluid will flow out after the rubber lines are moved from the hard lines.  TIP: Use a line clamp on the rubber power steering lines to prevent the power steering fluid from coming out.  This will save the majority of the power steering fluid and only require you to add a small amount of fluid to the power steering reservoir.

Installation

  1. OPTIONAL:   Install the new external power steering cooler - (If you do not have the VAG power steering fluid or if you want to use the OEM line, bend it upwards on the side of the FMIC).  You may attach it anywhere you like.  We recommend you attach it above the intercooler towards the driver’s side.  Slide the power steering cooler straps through the cooler and through the a/c condenser.  They do not need to go through the radiator.  Place the power steering cooler mounting cushions through the mounting straps so that they sit between the power steering cooler and the a/c condenser.  MAKE SURE THE EXTERNAL POWER STEERING COOLER CLEARS THE HOOD LATCH.  ONCE THE CLIP IS ATTACHED TO THE MOUNTING STRAPS, THEY CANNOT BE REMOVED WITHOUT CUTTING THEM (LIKE ZIP TIES).  Attach the clips to the straps.  Attach the longer hose to the top fitting on the external power steering cooler and the short one to the lower fitting.  Use supplied metal barbed hose connector to attach the new hose to the old stock soft (rubber) lines (top hose goes to top soft line, bottom hose goes to bottom line).  Attach clamps and tighten.
  2. Reattach the MAP sensor to the new throttle body intercooler pipe - The MAP sensor will now use (2) 6mm x 14mm long silver Allen bolts (which are supplied in the kit) to reattach itself to the new throttle body intercooler pipe.  DO NOT OVERTIGHTEN THE ALLEN BOLTS AS DOING SO WILL STRIP THE MOUNTING THREADS.
  3. Mount the ER Front Mount Intercooler - The FMIC mounts to the (4) T-25 Torx screws holding the A/C condenser to the radiator.  DO NOT TORQUE DOWN THE SCREWS.  HAND TIGHTEN SNUGLY.  THE RADIATOR ENDTANKS ARE MADE OUT OF PLASTIC AND IF YOU TORQUE THEM DOWN THEY WILL STRIP.  Attach the silicone hump couplings to the intercooler.
  4. Attach the new intercooler piping - The 2.25" intercooler piping is the turbo to intercooler piping.  The 2.5" intercooler piping with the MAP sensor flange is the throttle body pipe.  The other 2.5" intercooler piping attaches to the intercooler to the throttle body pipe.  Use the supplied t-bolt clamps.  DO NOT OVERTIGHTEN THE T-BOLT CLAMP.  THE T-BOLT CLAMPS CAN PRODUCE ENOUGH CLAMPING FORCE TO CRUSH THE INTERCOOLER PIPING.  Clamp the t-bolt clamps until they are hand tight.  Make sure the t-bolt clamps clear both the headlights assemblies or else you will have problems reinstalling the headlights.
  5. Modify and install the bumper reinforcement bar - Cut out the back portion of the bumper reinforcement bar so that it will clear the FMIC assembly.  Reinstall the bumper reinforcement bar to the bumper cover.
  6. Secure the sensor that was located on the OEM power steering hard line - Use the supplied zip ties and secure the sensor to the FMIC upper mount. 
  7. Start the car and check for boost leaks.
  8. Add power steering fluid to the power steering reservoir - Turn the steering wheel back and forth, adding fluid as need until squealing goes away and the reservoir fluid level stabilizes and is at the full mark.  USE ONLY AUDI/VW POWER STEERING FLUID ONLY. 
  9. Reassemble car – Follow Removal STEP 8 to 1 in reverse order. 
  10. Lower car back on the ground.
  11. Start the car and enjoy!

00-02 (B5) Audi S4 2.7TT Sports Series Dual Side Mount Intercooler (DSMIC) PARTS CHECKLIST

00-02 (B5) S4 2.7TT Sports DSMIC Full Kit

Intercooler Assembly - Driver's Side x1
Intercooler Assembly - Passenger Side x1
Carbon Fiber Shroud - Driver's Side x1
Carbon Fiber Shroud - Passenger Side x1
Lower Intercooler Pipe x1
Silicone Hose Coupler - 2.00" Hump x2
Silicone Hose Coupler - 2.00" Straight x1
T-Bolt Clamp - 2.00" (238) x6
Air Conditioning Canister Bracket x1
Horn Bracket x1
Bolt - 6mmx1.00 (20mm long) x4
Nut - 6mmx1.00 x4
Washer - 6mm x8
Documentation x1
Sticker Packet x1

00-02 (B5) Audi S4 2.7TT Sports Series Dual Side Mount Intercooler (DSMIC) INSTALLATION GUIDE

Tools Needed:

Full set of metric sockets and wrenches.

Philips screwdriver.

Flat head screwdriver.

Full set of Hex sockets and/or wrenches.

Full set of Torx sockets and/or screwdriver bits.

Drill & Bits.

Tools to cut plastic (dremel, sander etc...)

Parts Needed:

None

Install Time: 2-3 hours.

Difficulty (1 Easy, 5 Hard): 2

Removal

  1. Lift up the car:  Jack up the front of the car and put on stands.  ALWAYS PUT THE CAR ON STANDS WHENEVER YOU GO UNDERNEATH IT.  FAILURE TO DO SO MAY RESULT IN INJURY OR DEATH IF THE JACK FAILS.
  2. Remove the side grill/fog light covers:  They are held in place by clips. Grab the fog light covers by the edges and gently, but firmly pull forward.
  3. Unbolt the bumper reinforcement bar. Once the side grill/fog light covers are removed, the hex socket bolts holding the bumper reinforcement bar to the bumper reinforcement bar support shock can now be accessed. There is 1 hex socket bolt holding each side of the bumper reinforcement bar and is located right behind the fog light cover hole, towards the top.
  4. Remove lower engine guard:  The lower engine guard is attached by 8mm screws.  Remove screws and remove the lower engine guard.
  5. Remove wheel well/fender liner from the front bumper.
  6. Remove headlights. The headlights are attached by 3 Torx socket bolts. Two bolts are located on top of the headlight. The third bolt is located on the bottom of the headlight and can be access from a hole in the side fender. Unclip the headlight from their wiring harness.
  7. Remove the bumper. The bumper is now only held on by clips located on the sides of the bumper (by the wheel). Grab the bottom corner of the side of the bumper were the clips are located and gently, but firmly pull that corner outwards. Once the bottom clip releases, grab the top corner of the bumper and pull that corner outwards, which should release all the clips. BE VERY CAREFUL AND ALERT WHEN PULLING THE CORNERS OF THE BUMPER AS THE CLIPS AND/OR THE MOUNT CAN BREAK. IT TAKES SOME EFFORT TO UNCLIP THESE CLIPS BUT DOES NOT NEED YOUR FULL STRENGTH. Pull the bumper forward and unclip the fog lights from their wiring harness. Put a bucket underneath the headlight washer lines and unclip the line.
  8. Disconnect the radiator core support/lock carriage from the chassis:  IT IS NOT MANDATORY TO REMOVE THE RADIATOR CORE SUPPORT/LOCK CARRIAGE COMPLETELY OFF THE CAR.  ALL THAT IS REQUIRED IS TO PULL IT FORWARD ENOUGH SO THAT THE NEW SIDE MOUNT INTERCOOLERS CAN SLIDE INTO PLACE.  The radiator core support/lock carriage is held in place by (4) Torx bolts and (1) 10mm nut where the bumper reinforcement shocks are located.  They’re also held onto the fenders by (2) Torx T20 bolts (above the headlight) and (1) Torx T20 bolt (side of the headlight towards the fender).  TRACE THESE BOLTS AND NUTS WITH A MARKER.  THESE MARKS WILL BE USED TO PROPERLY REALIGN THE RADIATOR CORE SUPPORT/LOCK CARRIAGE TO THEIR ORIGINAL POSITION UPON INSTALLATION.
     

  9. Remove ALL OEM intercooler hoses:  There are intercooler hoses running from the turbochargers to the OEM intercoolers as well as “S” hoses running from the OEM intercoolers to the plastic bi-pipes.  Remove them all.
  10. Remove the stock side mount intercoolers: Remove the OEM intercooler shrouds.  Move the clips on the OEM intercooler shrouds away from the mounting pegs and pull the shroud away from the intercooler.  The OEM intercoolers are held onto the intercooler brackets by rubber grommets.  Pull the bottom of the intercooler forwards to release it from the lower mount on the bracket.  Once free of the lower mount, lift the intercooler upwards to lift it off the bracket.
  11. Remove the air conditioning canister from its bracket:  Behind the passenger side intercooler, there is an air conditioning canister.  The air conditioning canister is held in place by (2) 10mm nuts onto the intercooler bracket.  Remove the (2) 10mm nuts.  BE VERY CAREFUL WHEN HANDLING THE AIR CONDITIONING CANISTER AND LINES.  THEY ARE FRAGILE AND CAN BE DAMAGED.
  12. Remove the intercooler bracket:  The intercooler bracket is held in place by rivets.  Rivets are removed by drilling the center of the rivet with a drill bit until the drill bit punches through to the other side, which will release the rivet.  You may need to pry the rivet off once you drilled through it.  You may also cut the brackets instead if you’d prefer.
  13. Remove the driver’s side horn and bracket.

Installation

  1. Install the new air conditioning canister bracket:  Attach the air conditioning canister to the new air conditioning bracket using the original (2) 10mm nuts removed from the old bracket.  Attach the bracket to the chassis using the original (1) 10mm bolt.  BE VERY CAREFUL WHEN HANDLING THE AIR CONDITIONING CANISTER AND LINES.  THEY ARE FRAGILE AND CAN BE DAMAGED.
  2. Trim radiator core support/lock carriage:  The carbon fiber shrouds are designed to maximize cooling efficiency of our upgraded side mount intercoolers.  By trimming away parts of the radiator core support/lock carriage, more surface area of the intercooler will be exposed to direct air flow.  Trim the radiator core support/lock carriage up to the frame rail.  TEST FIT THE NEW SHROUDS ON THE INTERCOOLER AND USE THAT AS REFERENCE ON HOW MUCH TO REMOVE.
  3. Mount the side mount intercoolers:  Slide the new intercoolers into their position.  There is a mount on top of the intercooler end tank.  It attaches to the mount where the fender attaches to the radiator core support/lock carriage (next to the headlight). 
  4. Trim passenger side shroud to accommodate the tow hook:  There is a tow hook by the passenger side intercooler and shroud.  Test fit the new passenger side carbon fiber shroud on the car.  Mark the area where the tow hook is positioned in reference to the shroud and using the 2” hole saw, cut out a piece of the carbon fiber shroud that is marked.
  5. Mark and drill new pilot holes on the carbon fiber shroud:  Test fit the new carbon fiber shrouds on the intercoolers.  There is a shroud mounting plate on the side of the intercooler with 2 holes that will be used to secure the shroud to the intercooler.  While the shroud is in the correct area, mark the location of the 2 holes on the bracket onto the shrouds by pushing the tip of the marker through the 2 holes.  Use these marks as reference on where to drill the holes on the shroud.  Take a 1/8” or similar drill bit and make a pilot hole.  MAKE SURE YOU DRILL STRAIGHT INTO THE MARKS AND THAT THE DRILL BIT DOES NOT MOVE AWAY FROM THE MARKS WHILE DRILLING.  FAILING TO DO SO WILL CAUSE THE HOLES ON THE SHROUDS TO NOT ALIGN WITH THE HOLES ON THE BRACKET. 
  6. Mount the new carbon fiber shrouds on the intercooler:  There are 2 ways to mount the shrouds:  Reuse OEM shroud screw and screw clip:  Remove the screw clip from the OEM shroud by pulling the clip apart.  There is a hole on the OEM shroud where the clip used to be.  Find a drill bit that size and using that drill bit, drill the 2 pilot holes you’ve made on the carbon fiber shroud.  Install the OEM screw clip onto the carbon fiber shroud.  Enlarge the 2 holes on the shroud bracket so that the OEM screw can pass though them.  Put the carbon fiber shroud on the intercooler and tighten the screws.  Use the supplied nuts, washer and bolts:  Take a ¼” drill bit and enlarge the 2 pilot holes on the carbon fiber shroud.  Using the same drill bit, enlarge the holes on the shroud bracket on the intercooler.  Take the supplied 6mmx1.00 bolt, washer, and nuts supplied in the kit and put them through the 2 corresponding holes on the shroud mount and shroud.  There should be 1 washer on each side of the shroud.  Hand tighten the nut and bolt.   DO NOT OVERTIGHTEN AS THIS MAY DAMAGE THE SHROUD.
  7. Repeat STEPS 6 and STEP 7 on other intercooler.
  8. Install intercooler pipes and reattach “S” hose:  Attach the 2” silicone hump couplings included in the kit to the lower end tank inlet.  The intercooler pipe included is for the passenger side intercooler.  Use the supplied T-bolt clamp (size 238) to the lower intercooler piping.  Reattach the OEM “S” hose to the upper end tank outlet and bi-pipes.  Tighten all clamps.
  9. Reinstall the radiator core support/lock carriage back onto car:  ONE OF THE BUMPER REINFORCEMENT BAR SHOCK BOLTS CANNOT BE PUT BACK ONTO THE CAR (far left bolt on passenger and far right bolt on driver).  THE BOLT IS TOO LONG AND WILL HIT THE INTERCOOLER!!!
  10. Start the car and check for boost leaks.
  11. Install the driver’s side horn:  Install the new supplied horn bracket onto the original location along with the horn.  Rotate the horn until it will clear the bumper.
  12. Reinstall headlight:  Reverse instruction in Removal STEP 7, STEP 3 then STEP 2.
  13. Reinstall headlight:  Reverse instruction in Removal STEP 6 then STEP 5.
  14. Reinstall lower engine guard:  Reverse instruction in Removal STEP 4.
  15. Lower car.
  16. Enjoy!

If there are any problems or questions about installation, please contact us at contact@evolutionracewerks.com or (626) 814-3403.


02-05 (B6) Audi A4 1.8T Sports Series Front Mount Intercooler (FMIC) Kit PARTS CHECKLIST

02-05 (B6) A4 1.8T Sports FMIC Kit

Front Mount Intercooler Assembly x1
Turbo to Intercooler Pipe x1
Lower Intercooler Pipe to Throttle Body Pipe x1
Throttle Body Pipe x1
Silicone Hose Coupler - 2.00" Straight x1
Silicone Hose Coupler - 2.00" Hump x1
Silicone Hose Coupler - 2.25" Straight x1
Silicone Hose Coupler - 2.25" Hump x1
Silicone Hose Coupler - 2.50" Straight x1
T-Bolt Clamp - 2.00" (238) x4
T-Bolt Clamp - 2.25" (263) x4
T-Bolt Clamp - 2.50" (288) x2
1" Reinforced Hose x1
Hose Clamp - 1" x4
MAP Sensor Hex Bolt (6mmx1.00) 12mm long x2
Power Steering Cooler x1
Power Steering Hose x2
Power Steering Hose Clamps x6
Power Steering Hose Brass Barbed Connector x2
Power Steering Cooler Mounting Strap x4
Power Steering Cooler Mounting Clip x4
Power Steering Cooler Mounting Cushion x4
Smog Pump Relocation Bracket x1
Zip Ties x2
Documentation x1
Sticker Packet x1

02-05 (B6) Audi A4 1.8T Sports Series Front Mount Intercooler (FMIC) Kit INSTALLATION GUIDE

Tools Needed:

Full set of metric sockets and wrenches.

Philips screwdriver.

Flat head screwdriver.

Full set of Hex sockets and/or wrenches.

Full set of Torx sockets and/or screwdriver bits.

Tool to cut the bumper (dremel, sander, etc…)

Parts Needed:

Audi/VW Power Steering Fluid

Install Time: 4-5 hours.

Difficulty (1 Easy, 5 Hard): 2

Removal

  1. Lift up the car - Jack up the front of the car and put on stands.  ALWAYS PUT THE CAR ON STANDS WHENEVER YOU GO UNDERNEATH IT.  FAILURE TO DO SO MAY RESULT IN INJURY OR DEATH IF THE JACK FAILS.
  2. Remove lower engine guard - The lower engine guard is attached by 8mm screws.  Remove screws and remove the lower engine guard.  
  3. Remove wheel well/fender liner from the front bumper – Remove the 8mm screws holding the wheel liner to the front bumper.  Behind the wheel liner, there is one screw holding the lower side guards to the front bumper.
  4. Remove the side grill/fog light covers - They are held in place by clips. Grab the fog light covers by the edges and gently, but firmly pull forward
  5. Unbolt the bumper reinforcement bar - Once the side grill/fog light covers are removed, the hex socket bolts holding the bumper reinforcement bar to the bumper reinforcement bar support shock can now be accessed. There is (1) hex socket bolt holding each side of the bumper reinforcement bar and is located right behind the fog light cover hole, towards the top.
  6. Remove headlight – Headlight held in place by (4) Torx T30 screws.
  7. Unbolt the bumper from the fender - Unbolt the (3) 10mm bolts on each side of the front bumper from the fender.  Bolts located underneath and to the side of the headlights (front bumper and fenders meet).  Pull the side of the bumper away from the fender to release it.
  8. Remove front bumper - Disconnect the fog light and horn clips.  Disconnect the water lines going to water squirter.  Remove front bumper from the car.
  9. Remove the front bumper reinforcement bar – Remove bar from the front bumper reinforcement shocks.  DO NOT REMOVE FRONT BUMPER REINFORCEMENT SHOCKS FROM THE RADIATOR CORE SUPPORT!  Doing so will drop the radiator core support causing the headlights/hood to become misaligned.  If you do accidentally remove the bolts holding the front bumper reinforcement shocks from the radiator core support, you must push the whole core support upwards and line up and bolt in the bolts to where the indentation of where the bolt sat originally. 
  10. Remove radiator/air conditioning condenser shrouds and intercooler shrouds - You can trim the plastic shrouds around the Front Mount Intercooler if you want to retain them.  The intercooler shrouds are held on by clips.
  11. Remove the smog pump, bracket and lines – The smog pump is located underneath the passenger side frame rail.  The smog pump has 2 plastic lines coming from the front of the airbox and the side of the turbo.  Remove the lines.
  12. Disconnect the diverter valve hose from the diverter valve.
  13. Remove all intercooler hoses (pipes) - There are three total.
  14. Disconnect the MAP sensor – The MAP sensor is located on the top end tank of the OEM driver’s side intercooler.
  15. Remove the stock side mount intercooler and bracket - There are 3 bolts holding the bracket to the chassis (2 hex bolts in the front, (1) 10mm bolt behind the windshield washer fluid reservoir).  Use an extension and go through the wheel well to remove 10mm bolt.
  16. Remove the MAP sensor from the stock intercooler - BE CAREFUL WHEN REMOVING AND INSTALLING THE MAP SENSOR NOT TO DAMAGE THE O-RING. 
  17. Unclip the sensor located on the OEM power steering cooling hard line – It is located in front of the radiator/air conditioning condenser.
  18. OPTIONAL (If you do not have the VAG power steering fluid or if you want to use the OEM line, bend it upwards on the side of the FMIC).  SKIP REMOVAL STEP 19 if choose this route.
  19. Remove the power steering cooling hard line – The line connects to stock soft (rubber) line.  Have a bucket underneath the lines while you disconnect them as power steering will flow out after the hard line is removed from the soft lines.
  20. Remove OEM bumper reinforcement bar from the bumper.

Installation

  1. Mount the ER Front Mount Intercooler - The FMIC mounts to the bottom 2 screws holding the A/C condenser to the radiator.  DO NOT TORQUE DOWN THE SCREWS.  HAND TIGHTEN SNUGLY.  THE RADIATOR ENDTANKS ARE MADE OUT OF PLASTIC AND IF YOU TORQUE THEM DOWN THEY WILL STRIP.  Attach the silicone hump couplings to the intercooler.
  2. OPTIONAL:   Install the new external power steering cooler - (If you do not have the VAG power steering fluid or if you want to use the OEM line, bend it upwards on the side of the FMIC).  You may attach it anywhere you like.  We recommend you attach it above the intercooler towards the driver’s side.  Slide the power steering cooler straps through the cooler and through the a/c condenser.  They do not need to go through the radiator.  Place the power steering cooler mounting cushions through the mounting straps so that they sit between the power steering cooler and the a/c condenser.  MAKE SURE THE EXTERNAL POWER STEERING COOLER CLEARS THE HOOD LATCH.  ONCE THE CLIP IS ATTACHED TO THE MOUNTING STRAPS, THEY CANNOT BE REMOVED WITHOUT CUTTING THEM (LIKE ZIP TIES).  Attach the clips to the straps.  Attach the longer hose to the top fitting on the external power steering cooler and the short one to the lower fitting.  Use supplied metal barbed hose connector to attach the new hose to the old stock soft (rubber) lines (top hose goes to top soft line, bottom hose goes to bottom line).  Attach clamps and tighten.
  3. Attach smog pump to the new smog pump relocation bracket – Attach the smog pump to the new included bracket using the (3) factory 10mm nuts.  Reattach the hoses onto the smog/catalytic converter pump.  Once attached, twist the hose at the clip (apply some pressure) and the clip will now rotate the hose.  THE CLIP THAT ATTACHES TO THE PIPE BY THE TURBO WILL DOES NOT ROTATE.  DO NOT TRY TO TWIST THAT CLIP!  Do the same for the clip that goes to the stock airbox.  The new smog pump relocation bracket attaches to one of the original smog pump bracket mounting point.  Reattach the hoses going to the stock airbox and the pipe next to the turbo.
  4. Reattach the MAP sensor to the new throttle body pipe - (use lubrication) Use supplied Hex Bolt (6mmx1.0).  Attach the 2.5” silicone coupling to the throttle body.  Install the throttle body pipe.
  5. Install the new lower intercooler pipe to the intercooler and throttle body pipe – Use the supplied 2.5” silicone hump hose (intercooler side) and 2.5” silicone straight hose.
  6. Install the new turbo to intercooler pipe - Attach the 2.00” to 2.25” silicone transition to the turbo.  Attach the 2.25” silicone hump hose to the intercooler.  Attach the pipe to the turbo first then into the intercooler.
  7. Tighten all T-bolt clamps - Be careful to line the T-bolt clamps straight when tightening.  Do not over tighten.  T-bolt clamps have a lot of clamping force.  If over tightened, they will break/crack/contort the intercooler piping.
  8. Attach the 1” reinforced hose to the turbo to intercooler pipe - Remove the “T” connector from the diverter valve hoses.  Take the stock “T” connector and flip it so the “T” connector is upside down.  Reattach the diverter valve hoses.  Attach the 1” reinforcement hose to the stock “T” connector.  Attach supplied clamps and tighten.
  9. Reattach the factory bumper reinforcement bar.
  10. Use supplied zip ties to secure the senor clip from the OEM power steering cooler to the new bumper reinforcement bar.
  11. Add power steering fluid to the power steering reservoir - Turn the steering wheel back and forth, adding fluid as need until squealing goes away and the reservoir fluid level stabilizes and is at the full mark.  USE ONLY AUDI/VW POWER STEERING FLUID ONLY.
  12. Start the car and check for boost leaks.
  13. Trim bumper cover for the new front mount intercooler - On OEM and Ultrasport bumpers, trimming is only required on the bottom sides of the bumper (due to the slope and curvature of the OEM and Ultrasport bumpers).  The OEM center grill and side fog light covers can be retained (IF COVERS ARE RETAINED, DO NOT TRIM OFF MOUNTING POINTS ON THE BUMPER).  Most aftermarket bumpers do not require trimming. 
  14. Reassemble car – Follow Removal STEP 8 to 1 in reverse order.
  15. Lower car back on the ground.
  16. Start the car and enjoy!

If there are any problems or questions about installation, please contact us at contact@evolutionracewerks.com or (626) 814-3403.


02-05 (B6) Audi A4 1.8T Competition Series Front Mount Intercooler (FMIC) Kit PARTS CHECKLIST

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02-05 (B6) Audi A4 1.8T (all) Competition FMIC Full Kit

Front Mount Intercooler Assembly x1
Turbo to Intercooler Pipe x1
Lower Intercooler Pipe to Throttle Body Pipe x1
Throttle Body Pipe x1
Silicone Hose Coupler - 2.00" to 2.25" Transition x1
Silicone Hose Coupler - 2.25" Hump x1
Silicone Hose Coupler - 2.50" Hump x1
Silicone Hose Coupler - 2.50" Straight x2
T-Bolt Clamp - 2.00" (238) x1
T-Bolt Clamp - 2.25" (263) x3
T-Bolt Clamp - 2.50" (288) x6
1" Reinforced Hose x1
Hose Clamp - 1" x4
MAP Sensor Hex Bolt (6mmx1.00) 12mm long x2
Power Steering Cooler x1
Power Steering Hose x2
Power Steering Hose Clamps x6
Power Steering Hose Brass Barbed Connector x2
Power Steering Cooler Mounting Strap x4
Power Steering Cooler Mounting Clip x4
Power Steering Cooler Mounting Cushion x4
Smog Pump Relocation Bracket x1
Bumper Reinforcement Bar x1
Horn Strap Mount x2
8mmx1.25 Nut x2
Zip Ties x2
Documentation x1
Sticker Packet x1

02-05 (B6) Audi A4 1.8T Competition Series Front Mount Intercooler (FMIC) Kit INSTALLATION GUIDE

Tools Needed:

Full set of metric sockets and wrenches.

Philips screwdriver.

Flat head screwdriver.

Full set of Hex sockets and/or wrenches.

Full set of Torx sockets and/or screwdriver bits.

Tool to cut the bumper (dremel, sander, etc…)

Parts Needed:

Audi/VW Power Steering Fluid

Install Time: 4-5 hours.

Difficulty (1 Easy, 5 Hard): 2

Removal

  1. Lift up the car - Jack up the front of the car and put on stands.  ALWAYS PUT THE CAR ON STANDS WHENEVER YOU GO UNDERNEATH IT.  FAILURE TO DO SO MAY RESULT IN INJURY OR DEATH IF THE JACK FAILS.
  2. Remove the side grill/fog light covers - They are held in place by clips. Grab the fog light covers by the edges and gently, but firmly pull forward.
  3. Unbolt the bumper reinforcement bar - Once the side grill/fog light covers are removed, the hex socket bolts holding the bumper reinforcement bar to the bumper reinforcement bar support shock can now be accessed. There is (1) hex socket bolt holding each side of the bumper reinforcement bar and is located right behind the fog light cover hole, towards the top. 
  4. Remove lower engine guard - The lower engine guard is attached by 8mm screws.  Remove screws and remove the lower engine guard.   
  5. Remove wheel well/fender liner from the front bumper – Remove the 8mm screws holding the wheel liner to the front bumper.  Behind the wheel liner, there is one screw holding the lower side guards to the front bumper.  
  6.  Remove headlight – Headlight held in place by (4) Torx T30 screws.  
  7.  Unbolt the bumper from the fender - Unbolt the (3) 10mm bolts on each side of the front bumper from the fender.  Bolts located underneath and to the side of the headlights (front bumper and fenders meet).  Pull the side of the bumper away from the fender to release it.  
  8. Remove front bumper - Disconnect the fog light and horn clips.  Disconnect the water lines going to water squirter.  Remove front bumper from the car. 
  9. Remove the front bumper reinforcement bar– Remove bar from the front bumper reinforcement shocks.  DO NOT REMOVE FRONT BUMPER REINFORCEMENT SHOCKS FROM THE RADIATOR CORE SUPPORT!  Doing so will drop the radiator core support causing the headlights/hood to become misaligned.  If you do accidentally remove the bolts holding the front bumper reinforcement shocks from the radiator core support, you must push the whole core support upwards and line up and bolt in the bolts to where the indentation of where the bolt sat originally.  
  10. Remove radiator/air conditioning condenser shrouds and intercooler shrouds - You can trim the plastic shrouds around the Front Mount Intercooler if you want to retain them.  The intercooler shrouds are held on by clips.  
  11. Remove the smog pump, bracket and lines – The smog pump is located underneath the passenger side frame rail.  The smog pump has 2 plastic lines coming from the front of the airbox and the side of the turbo.  Remove the lines. 
  12. Disconnect the diverter valve hose from the diverter valve.  
  13. Remove all intercooler hoses (pipes) - There are three total. 
  14. Disconnect the MAP sensor – The MAP sensor is located on the top end tank of the OEM driver’s side intercooler 
  15. Remove the stock side mount intercooler and bracket - There are 3 bolts holding the bracket to the chassis (2 hex bolts in the front, (1) 10mm bolt behind the windshield washer fluid reservoir).  Use an extension and go through the wheel well to remove 10mm bolt. 
  16. Remove the MAP sensor from the stock intercooler - BE CAREFUL WHEN REMOVING AND INSTALLING THE MAP SENSOR NOT TO DAMAGE THE O-RING.  
  17. Unclip the sensor located on the OEM power steering cooling hard line – It is located in front of the radiator/air conditioning condenser. 
  18. OPTIONAL (If you do not have the VAG power steering fluid or if you want to use the OEM line, bend it upwards on the side of the FMIC).  SKIP REMOVAL STEP 19 if choose this route. 
  19. Remove the OEM power steering hard line - Unclip the sensor attached to the OEM power steering hard line (located in front of the car).  Remove the OEM power steering hard line from the stock rubber line (have a bucket underneath as power steering fluid will flow out after the rubber lines are moved from the hard lines.  TIP: Use a line clamp on the rubber power steering lines to prevent the power steering fluid from coming out.  This will save the majority of the power steering fluid and only require you to add a small amount of fluid to the power steering reservoir.
  20. Remove OEM bumper reinforcement bar from the bumper.

Installation

  1. Mount the ER Front Mount Intercooler - The FMIC mounts to the 4 screws holding the A/C condenser to the radiator.  DO NOT TORQUE DOWN THE SCREWS.  HAND TIGHTEN SNUGLY.  THE RADIATOR ENDTANKS ARE MADE OUT OF PLASTIC AND IF YOU TORQUE THEM DOWN THEY WILL STRIP.  Attach the silicone hump couplings to the intercooler.
  2. OPTIONAL:   Install the new external power steering cooler - (If you do not have the VAG power steering fluid or if you want to use the OEM line, bend it upwards on the side of the FMIC).  You may attach it anywhere you like.  We recommend you attach it above the intercooler towards the driver’s side.  Slide the power steering cooler straps through the cooler and through the a/c condenser.  They do not need to go through the radiator.  Place the power steering cooler mounting cushions through the mounting straps so that they sit between the power steering cooler and the a/c condenser.  MAKE SURE THE EXTERNAL POWER STEERING COOLER CLEARS THE HOOD LATCH.  ONCE THE CLIP IS ATTACHED TO THE MOUNTING STRAPS, THEY CANNOT BE REMOVED WITHOUT CUTTING THEM (LIKE ZIP TIES).  Attach the clips to the straps.  Attach the longer hose to the top fitting on the external power steering cooler and the short one to the lower fitting.  Use supplied metal barbed hose connector to attach the new hose to the old stock soft (rubber) lines (top hose goes to top soft line, bottom hose goes to bottom line).  Attach clamps and tighten. 
  3. Attach smog pump to the new smog pump relocation bracket – Attach the smog pump to the new included bracket using the (3) factory 10mm nuts.  Reattach the hoses onto the smog/catalytic converter pump.  Once attached, twist the hose at the clip (apply some pressure) and the clip will now rotate the hose.  THE CLIP THAT ATTACHES TO THE PIPE BY THE TURBO WILL DOES NOT ROTATE.  DO NOT TRY TO TWIST THAT CLIP!  Do the same for the clip that goes to the stock airbox.  The new smog pump relocation bracket attaches to one of the original smog pump bracket mounting point.  Reattach the hoses going to the stock airbox and the pipe next to the turbo. 
  4. Reattach the MAP sensor to the new throttle body pipe - (use lubrication) Use supplied Hex Bolt (6mmx1.0).  Attach the 2.5” silicone coupling to the throttle body.  Install the throttle body pipe. 
  5. Install the new lower intercooler pipe to the intercooler and throttle body pipe – Use the supplied 2.5” silicone hump hose (intercooler side) and 2.5” silicone straight hose. 
  6. Install the new turbo to intercooler pipe - Attach the 2.00” to 2.25” silicone transition to the turbo.  Attach the 2.25” silicone hump hose to the intercooler.  Attach the pipe to the turbo first then into the intercooler. 
  7. Tighten all T-bolt clamps - Be careful to line the T-bolt clamps straight when tightening.  Do not over tighten.  T-bolt clamps have a lot of clamping force.  If over tightened, they will break/crack/contort the intercooler piping. 
  8. Attach the 1” reinforced hose to the turbo to intercooler pipe - Remove the “T” connector from the diverter valve hoses.  Take the stock “T” connector and flip it so the “T” connector is upside down.  Reattach the diverter valve hoses.  Attach the 1” reinforcement hose to the stock “T” connector.  Attach supplied clamps and tighten. 
  9. Attach the new bumper reinforcement bar to the stock bumper reinforcement shocks - Reuse the stock bolts but use the supplied nut (8mmx1.25). 
  10. Attach the horn straps to the new bumper reinforcement bar - Use the stock bolt that attaches the bumper reinforcement bar to the stock bumper reinforcement shocks (big hole on this side).  Make sure the straps will clear bumper before tightening.  Attach OEM horns to the horn strap using the OEM nut. 
  11. Use supplied zip ties to secure the sensor clip from the OEM power steering cooler to the new bumper reinforcement bar. 
  12. Add power steering fluid to the power steering reservoir - Turn the steering wheel back and forth, adding fluid as need until squealing goes away and the reservoir fluid level stabilizes and is at the full mark.  USE ONLY AUDI/VW POWER STEERING FLUID ONLY. 
  13. Start the car and check for boost leaks. 
  14. Trim bumper cover for the new front mount intercooler - On OEM and Ultrasport bumpers, trimming is only required on the bottom sides of the bumper (due to the slope and curvature of the OEM and Ultrasport bumpers).  The OEM center grill and side fog light covers can be retained (IF COVERS ARE RETAINED, DO NOT TRIM OFF MOUNTING POINTS ON THE BUMPER).  Most aftermarket bumpers do not require trimming.  
  15. OPTIONAL: If fog lights are retained, remove the adjustment screw from the driver’s side fog light and trim the inside of the bumper cover.  Very light trimming is needed to properly clear the driver’s side fog light housing; however it can be installed without trimming the driver’s side fog light housing (your own discretion). 
  16. Reassemble car – Follow Removal STEP 8 to 1 in reverse order. 
  17. Lower car back on the ground.
  18. Start the car and enjoy!

If there are any problems or questions about installation, please contact us at contact@evolutionracewerks.com or (626) 814-3403.


96-01 (B5) Audi A4 1.8T Competition Series Front Mount Intercooler (FMIC) Kit PARTS CHECKLIST

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1996-01 (B5) Audi A4 1.8T (DBW) Competition FMIC Full Kit

Front Mount Intercooler Assembly x1
Intercooler Assembly Mounts x2
Turbo to Intercooler Pipe x1
Intercooler to Throttle Body Pipe x1
Silicone Hose Coupler - 2.00" to 2.25" Transition x1
Silicone Hose Coupler - 2.25" Hump x1
Silicone Hose Coupler - 2.50" Hump x1
Silicone Hose Coupler - 2.50" Straight x1
T-Bolt Clamp - 2.00" (238) x1
T-Bolt Clamp - 2.25" (263) x3
T-Bolt Clamp - 2.50" (288) x4
1" Reinforced Hose x1
Hose Clamp - 1.00" x3
MAP Sensor Hex Bolt (6mmx1.00) 14mm Long x2
Power Steering Cooler x1
Power Steering Hose x2
Power Steering Hose Clamp x6
Power Steering Hose Barbed Hose Connectors x2
Power Steering Cooler Mounting Straps x4
Power Steering Cooler Mounting Strap Clips x4
Power Steering Cooler Mounting Cushions x4
Smog Pump Relocation Bracket x1
Smog Pump Ring Bracket x1
Bumper Reinforcement Bar x1
Horn Relocation Bracket x1
A/C Canister Bracket x1
6mmx1.00 Bolt (10mm hex) x2
8mmx1.25 Nut x3
Zip Ties x2
Documentation x1
Sticker Packet x1

96-01 (B5) Audi A4 1.8T Competition Series Front Mount Intercooler (FMIC) Kit INSTALLATION GUIDE

Tools Needed:

Full set of metric sockets and wrenches.

Philips screwdriver.

Flat head screwdriver.

Full set of Hex sockets and/or wrenches.

Full set of Torx sockets and/or screwdriver bits.

Tool to cut the bumper (dremel, sander, etc…)

Parts Needed:

Audi/VW Power Steering Fluid

Install Time: 4-5 hours.

Difficulty (1 Easy, 5 Hard): 2

Removal:

  1. Jack the front end of the car up.
  2. Remove fog light covers. They are held in place by clips. Grab the fog light covers by the edges and gently, but firmly pull.
  3. Unbolt the bumper reinforcement bar. Once the fog light covers are removed, the hex socket bolts holding the bumper reinforcement bar to the bumper reinforcement bar support shock can now be accessed. There is 1 hex socket bolt holding each side of the bumper reinforcement bar and is located right behind the fog light cover hole, towards the top.
  4. Remove the belly pan cover.
  5. Remove the bumper. The bumper is now only held on by clips located on the sides of the bumper (by the wheel). Grab the bottom corner of the side of the bumper were the clips are located and gently, but firmly pull that corner outwards. Once the bottom clip releases, grab the top corner of the bumper and pull that corner outwards, which should release all the clips. BE VERY CAREFUL AND ALERT WHEN PULLING THE CORNERS OF THE BUMPER AS THE CLIPS AND/OR THE MOUNT CAN BREAK. IT TAKES SOME EFFORT TO UNCLIP THESE CLIPS BUT DOES NOT NEED YOUR FULL STRENGTH. Pull the bumper forward and unclip the fog lights from their wiring harness. Put a bucket underneath the headlight washer lines and unclip the line.
  6. Remove headlights. The headlights are attached by 3 Torx socket bolts. Two bolts are located on top of the headlight. The third bolt is located on the bottom of the headlight and can be access from a hole in the side fender. Unclip the headlight from their wiring harness.
  7. Remove the OEM radiator shrouds. They are held onto the sides of the radiator by 2 Philips screws.
  8. Detach the OEM power steering cooler (metal line running in front of the radiator and the air conditioning condenser) from the radiator core support / lock carriage. It is attached to the radiator core support / lock carriage by one 10mm bolt. DO NOT DETACH THE POWER STEERING LINES YET.
  9. Remove the OEM side mount intercooler shroud from the intercooler.
  10. Remove the OEM intercooler hoses. Detach the hose clamps holding the intercooler hose connecting the turbocharger to the intercooler hard piping on the radiator core support / lock carriage. Detach the hose clamps holding the diverter valve to this intercooler hose. Remove the intercooler hose. Detach the hose clamps holding the intercooler hose connecting the intercooler hard piping on the radiator core support / lock carriage to the side mount intercooler. Remove the intercooler hose. Detach the hose clamps holding the intercooler hose connecting the side mount intercooler to the throttle body. Unclip the MAP sensor located on the top of the side mount intercooler end tank from its harness (does not apply to pre-2000 models as they do not have this MAP sensor).
  11. Remove the bumper reinforcement bar.
  12. Unbolt the radiator core support / lock carriage from the chassis. TRACE ALL BOLTS HOLDING THE RADIATOR CORE SUPPORT / LOCK CARRIAGE TO THE CHASSIS WITH A MARKER. THIS WILL HELP WITH ALIGNING THE RADIATOR CORE SUPPORT / LOCK CARRIAGE BACK ONTO THE CHASSIS. Remove the 2 Torx socket bolts located on the top of the radiator core support / lock carriage, next to the side fenders. Remove the Torx bolt holding the side of the radiator core support / lock carriage to the side fender. Remove the bumper reinforcement bar support shock from the radiator core support / lock carriage. It is held on by 3 large Torx socket bolts and one 10mm nut. Once all bolts and nuts holding the radiator core support / lock carriage has been removed, pull it slightly forward away from the chassis. DO NOT REMOVE THE RADIATOR CORE SUPPORT / LOCK CARRIAGE COMPLETELY FROM THE CHASSIS. IT IS NOT NECCESARY.
     

  13. Remove the OEM side mount intercooler from its bracket. Once the OEM side mount intercooler has been removed from the car, remove the MAP sensor (2000-up models only) from the side mount intercooler (does not apply to pre-2000 models as they do not have this MAP sensor). BE CAREFUL WHEN REMOVING AND HANDLING THE MAP SENSOR AS IT IS FRAGILE.
  14. Reinstall the radiator core support / lock carriage onto the chassis. Use the marker tracings made earlier to align the radiator core support / lock carriage to its previous location.
  15. Remove the smog pump / air conditioning bracket (early model do not have smog pumps). The smog pump is held onto the chassis by a bracket that also holds the air conditioning bracket. This bracket needs to be removed to relocate the smog pump. This bracket is held to the chassis by three 10mm bolts. One bolt is located on top of the smog pump on the frame rail. The other 2 bolts are behind the air conditioning canister. Unbolt the air conditioning canister from its bracket. It is held on by two 10mm nuts on the side of the air conditioning bracket. The bracket can now be removed from the car. Once the bracket has been removed from the car, remove the smog pump from the bracket. It is held on by three 10mm nuts.
     
  16. Remove the passenger side horn. The passenger side horn is held in place by a bracket that is attached to the passenger side of the radiator core support / lock carriage. Remove both the horn and bracket. Unclip the horn from its wiring harness.
  17. Remove the OEM power steering cooler. Break the OEM metal ties that secure the OEM power steering lines to the OEM power steering cooler. Drain the power steering fluid into a bucket. If you want to save as much power steering fluid as possible, you can use vice-grips or locking hose pliers to pinch the power steering lines. WHEN PINCHING THE POWER STEERING LINES, ENSURE YOU DO NOT PINCH THE LINE TOO TIGHT AS THAT CAN LEAD TO DAMAGE TO THE LINES.

Installation:

  1. Install new air conditioning canister bracket. Reuse one 10mm bolt that held the original smog pump / air conditioning canister bracket to the chassis. Attach the 10mm bolt to one of the original mounting points as well (bottom side bolt holding the original bracket). Attach the other end of the new air conditioning bracket to the air conditioning canister with one of the original 10mm nuts.
  2. Install the new horn bracket. On the side of the air conditioning canister, there is a 10mm bolt holding a spring hook that is holding the air conditioning line that runs underneath the air conditioning canister in place. Remove this bolt and attach the new horn bracket to this mounting point with the bracket pointing forward. Attach the horn to the new horn bracket. Align the horn so that it will clear both the side fender, air conditioning line and the bumper. Tighten the bolt holding the new horn bracket to the spring hook mounting point. Tighten the horn to the new horn bracket. Clip the horn harness back onto the horn.
  3.  Install the new external power steering cooler. CHECK THE CLEARANCE OF THE HOOD WHEN IT IS CLOSED WHEN MOUNTING THE NEW EXTERNAL POWER STEERING COOLER. ENSURE THAT THERE IS MORE THAN ADEQUATE ROOM WHEN THE HOOD IS CLOSED. THIS IS DUE TO THE FACT THAN WHEN THE HOOD IS SLAMMED CLOSED, IT CAN MOVE LOWER THAN WHERE THE HOOD NORMALLY SITS. THE EXTERNAL POWER STEERING SHOULD SIT TOWARDS THE DRIVER’S SIDE OF THE AIR CONDITIONING CONDENSER / RADIATOR, DIRECTLY ABOVE THE INTERCOOLER. The new external power steering cooler is mounted to the air conditioning condenser by the included mounting strap. Slide the mounting strap through the new external power steering cooler. Attach the mounting cushions behind the new external power steering cooler where the mounting straps go through. Position the new external power steering cooler and slide the mounting straps through the air conditioning condenser. Unbolt the air conditioning condenser. Slide the mounting strap clips onto the mounting straps from the back side of the air conditioning condenser and pull until the new external power steering cooler is tight against the air conditioning condenser. Cut off the excess mounting strap. 
  4. Mount the Front Mount Intercooler. The air conditioning condenser is held in place against the radiator through brackets on both sides, each with two 10mm bolts (4 total). The bottom 10mm bolt on each side is used to attach (unthreaded hole) the new intercooler mount brackets (long aluminum strap). The intercooler itself bolts to the threaded holes on the bottom of the intercooler mount brackets to the supplied 10mm bolt (6mmx1.00). Due to the design of the mounting system, the intercooler core assembly can be adjusted horizontally, giving you the ability to align the intercooler core assembly perfectly center to your bumper. ALIGN THE INTERCOOLER CORE ASSEMBLY TO CENTER BEFORE TIGHTENING MOUNTING BOLTS. Tighten all the mounting bolts. DO NOT OVERTIGHTEN THE MOUNTING BOLTS AS THIS MAY STRIP THE THREADS THAT THE BOLT ATTACHES TO.
  5. Install the OEM smog pump (if car is equipped with one). Attach the OEM smog pump to the new supplied smog pump bracket ring (big ring with 3 holes in it) with the original three 10mm nuts. The OEM smog pump lines can turn at the attachment joint, however they need to be “broken” loose. Attach the OEM smog pump lines to the OEM smog pump. Once attached, grip the line at the attachment joint and turn them to “break” them loose. Once “broken” loose, they can turn freely. Do the same to the other end of the OEM smog pump lines. CLOSELY INSPECT EACH END OF THE ATTACHMENT JOINT. ONE SIDE OF THE OEM SMOG PUMP LINE IS FIXED AND CANNOT BE TURNED. The new supplied smog pump “L” bracket is attached to the hole in the radiator core support / lock carriage where the OEM horn bracket originally attached. Reuse the original bolt use to attach the OEM horn bracket and the supplied new 12mm (8mmx1.25) nut to attach the new smog pump “L” bracket. Attach the OEM smog pump to the new smog pump “L” bracket through one of the three 10mm nut holding the smog pump to the new smog pump bracket ring. ENSURE THAT THE SMOG PUMP IS ORIENTED SO THAT THE INLET AND OUTLET ARE POINTING AT THE RADIATOR CORE SUPPORT / LOCK CARRIAGE. Reattach OEM smog pump lines to their respective locations on the OEM airbox and on the pipe (sitting next to the turbocharger) leading to the smog pump valve. 
  6. Install the intercooler “cold” pipe (intercooler to throttle body pipe) and intercooler “hot” pipe (turbo to intercooler pipe). Install the MAP sensor (if applicable) removed from the OEM intercooler assembly onto the flange on the intercooler “cold” pipe (does not apply to pre-2000 models as they do not have this MAP sensor). Use the supplied 5mm (6mmx1.00) hex socket bolts to attach the sensor. DO NOT OVERTIGHTEN THESE BOLTS AS THIS MAY STRIP THE THREADS ON THE FLANGE THAT THE BOLT ATTACHES TO. Install the intercooler “cold” pipe on the car. Install the intercooler “hot” pipe on the car. ENSURE THAT THE T-BOLT CLAMPS ARE FLUSH AGAINST THE SILICONE HOSE COUPLER AND ARE FULLY TIGHTENED. THE NYLON LINED NUT ON THE T-BOLT CLAMP WILL GIVE THE TENSION WHEN TIGHTENING AND MAY GIVE THE ILLUSION THAT THEY ARE TIGHT. DO NOT OVERTIGHTEN THE T-BOLT CLAMP. THEY HAVE VERY HIGH CLAMPING LOADS AND CAN DEFORM AND DAMAGE THE INTERCOOLER PIPE IF OVER TIGHTENED.

  7. Install the diverter valve. Attach the diverter valve with the 1” reinforced hose. Tighten the supplied 1” hose clamps.
  8. Add power steering fluid to the power steering reservoir. Turn the steering wheel back and forth, adding fluid as need until squealing goes away and the reservoir fluid level stabilizes and is at the full mark. USE ONLY AUDI/VW POWER STEERING FLUID ONLY.
  9. Start the car and check for boost leaks. Turn off car.
  10. Install the new bumper reinforcent bar - Use the original hex socket bolt.
  11. Reinstall front bumper and headlights. Reattach the fog light clips, headlight washer clips and hoses. Reattach front bumper. Reattach headlights.
  12. Reinstall the belly pan cover.
  13. Lower the car.
  14. Enjoy!

If there are any problems or questions about installation, please contact us at contact@evolutionracewerks.com or (626) 814-3403.

 


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