Kokeln Intercooler
After running the IC fan for a while and being quite satsified I was convinced that I needed to go to the Kokeln IC.
In working on my car I saw that I had some serious damage to the pop-off valve assembly where the IC mounts to it. I was thinking of just buying the new Imagine Auto Pop off valve assembly but then it would be useless if I went to a new IC.
I had been afraid of needing a head rebuild so I figured I had already spent the money in my mind and that was that.
That is all there was to it!
You can see the difference between the two coolers here.
The install process is not difficult but the directions from Vision are bad and I needed lots of help from Stephen to get things right.
First you remove the stock IC by loosening the three mounting points (one on the passenger side, one on the driver side and one on the fan housing). You will also have to disconnect at least one vacum/boost line and the line to the Auxiliary air valve.
Next you remove the stock BOV assembly. This should be secured by another three bolts; one on the passenger side top one on the driver side at the back (hidden side) and one near to you(car's rear) on the same side. You will also need to deal with the recirculate valve and the vacum line to the TB. This line is a good place to pull manifold pressure for the new BOV. The odd Y shaped pipe can be plugged, removed or just recirculated(That is what I did b.c it was easiest. I just hooked a hose to both ends and clamped it in place)
After you loosen the hose clamps to free the BOV assembly you will see where the new sleeve piece goes and will be able to remove the elbow from the CIS to install the new elbow provided with the kit. This is where the new C2 style BOV actually mounts. This is a good time to replace aging hose or damaged clamps.
This is what the new sleeve and elbow look like installed.
This is the engine comprtment ready for the new IC to be installed
Before installing the new IC you need to swap over the boost pressure and overboost sensor from you old BOV assembly. The over boost is critical. If not instaleld correctly you will not go anywere! You also need to screw in the barbed fitting for your boost line and for the AUX air line.
Here is the IC mounted in the car. I later developed a leak because I was lacking a large black rubber gasket on my boost pipe and that kept the IC from seating properly. When installed it was actually so well isolated that I had to add a ground wire so my overboost sensor would work!
And finally the lines should all be hooked up (boost, aux air, overboost etc)
