Air to water intercooler in a wagon

[A.J.]

So I had TU's T-II aluminum radiator, a Volvo two speed fan (high moves A LOT of air) and with a front mount air to air intercooler it would run at 230* on the highway with the AC on in an Arizona summer. So I took the T-II radiator out, put in the factory full size and removed the FMIC. Well I need an intercooler because 7 lbs of boost is not fun and 15 lbs is. I bought an AWIC for my van and out grew it so I decided to put it in the wagon. The only things I had to buy was a water pump (I went with the cheaper bilge pump http://www.frozenboost.com/liquid-ai...mp-p-1000.html instead of the more expensive Bosch pump that I bought for my van, some 90* 1/2 NPT-3/4" barb fittings and a new heater hose to thermostat housing barb. Everything else I had lying around. I also had to relocate the battery to the trunk. I'm not racing this at the track anymore so it doesn't matter. Once this battery dies I might buy the thinner Honda battery to put it back under the hood.

I also figured out the water pump placement and bleeds on my first try, NO AIR POCKETS. I think the key is to put the pump low and have it push through the intercooler only.

The air to air FMIC:


AWIC:




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Heat exchanger:


Water pump:


I used the factory BOV for now. You can see a little of it here on the lower pipe under the IAC:


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And the relocated battery:


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And the relocated battery:

[Vigo]

Looking good. Have you had it back to the same boost level to get some butt dyno impressions?

[5DIGITS]

Excellent packaging job - reeeeeally looks clean and well placed.

[ShelGame]

I like it. I'm wanting to do the same thing with my next project. What I/C is that? eBay 12x12x4?

[GLHNSLHT2]

It's this kit from frozen boost Rob

http://www.frozenboost.com/liquid-ai...er-p-1034.html


Frozenboost has genuine water/air cores. I wouldn't trust ebay.

[A.J.]

Looking good. Have you had it back to the same boost level to get some butt dyno impressions?

No butt dyno difference except for the fact I can turn up the boost to 15 from the 7 I've had to drive with for lack of an intercooler.

[Pat]

Very clean install! I like it.

[Dr. Johny Dodge]

thanks muchly for the pics !!

it's good to see the relationship of the parts all fitted together so clearly as I'm interested in this same / simular set up - though I'd like to use the wider version of the I/C myself

[ShelGame]

It's this kit from frozen boost Rob

http://www.frozenboost.com/liquid-ai...er-p-1034.html

Frozenboost has genuine water/air cores. I wouldn't trust ebay.

Nice. I see they have one smaller than the 12x12 common on eBay. Not much more expensive either.

[iTurbo]

Very nice installation! Reminds me of the way the Spearco intercooler kits for the log Tis looked that were sold back in the 80s/90s.

Where did you get your air intake setup? That looks really good too.

[Dr. Johny Dodge]

looks like the factory air cleaner canister / drum thingy from my 01 f150 'cept maybe slightly smaller like it's from another model of ford

the aftermarket volant cold air kit I have in my truck now might also work nicely
http://www.sfxperformance.com/parts/VOL19854.htm

the opening before the filter is considerably larger than the stock one in the ford air filter can

[A.J.]

Very nice installation! Reminds me of the way the Spearco intercooler kits for the log Tis looked that were sold back in the 80s/90s.

Where did you get your air intake setup? That looks really good too.

That one is out of a Ford Explorer. I have one from an F-150 on my mini-van. The end of the air box is cut off to 1) allow more air in and 2) to adapt it to the SMEC. I then used silicone hoses and steel exhaust pipe with a 20* bend and another straight piece welded on at an angle to get the angle I needed up connect the air filter and get around the ic and brake master cylinder.

[GLHNSLHT2]

wow Johnny, 18hp over stock for that setup. Stock must be pretty restrictive.

[Dr. Johny Dodge]

yeah Idono about 18 hp - maybe on a 550 hp motor but not mine

it was good for an extra 2 mpg average driveing a steady 45-55 mph for 2-3 hours the night I put it in the truck though

stock set up is restrictive enough it makes (made) a sucking sound when you step into it before I swaped in that air box

I'd love to stuff an accel foam power filter in it but I thunk the mustang guys must have bought then all up as I searched hard and found none for ford
I did find one for the stock 2.2 air boxes though - those are still out there

accel power filters were discontinued long long ago - sad 'cause they were the best performance filter to be had - K&N looks like a joke compared to it

[contraption22]

Nice work AJ! Looks nice and tidy!

[ShadowFromHell]

I've got one of these ICs stashed away. It's actually a XSpower unit, I bought it before the knockoffs and paid a ton for it. I like the over the tranny mounting but it looks like a PITA to time the car. How hard is it? Do you have to remove the IC?

[Dr. Johny Dodge]

I asked about setting timeing on the other site before I bought the 588 trans with no window

NAJ over there said use the scaner tool for timeing

[A.J.]

I like the over the tranny mounting but it looks like a PITA to time the car. How hard is it? Do you have to remove the IC?

I didn't even think about that. I'll have to check. Even if I have to remove it, how often do you have to time your engine? I'll take having to remove the ic to time it over having no ic or a fmic and 230* engine temps on the highway.

[GLHNSLHT2]

2 hose clamps and the way it is in my friends van if we can't see the timing window 1 bolt and it slides over out of the way, don't even have to disconnect the water. Like AJ says how often do you time the car.

[iTurbo]

So on AJ's setup, are the intercooler pipes reduced to nil? Just a few couplers then?

I'm definitely going to look into this for my next setup.