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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


  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.


  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 or (626) 814-3403.