Ok so Iíve seen a few people asking about nb intercooler setups while keeping ac/ps so I figured Iíd start a thread on how I did mine. Iím definitely not the first to do this. I actually got the idea from one of 18psiís builds and I think he got it from someone else. Regardless of whos idea it is, heres how I got it to work on mine. There is a hole behind the driver side headlight. Obviously its too small for a pipe but can easily be expanded to fit a 2.5Ē i/c pipe. Then its just a 90* into the intercooler. The cold side is fairly straight forward and similar to other year models. Just down and around the radiator.
One issue I did have was mounting the intercooler because of the a/c canister. If I recall correctly my i/c is a 27"X5.5"X2.5" ebay special. I donít think a 3Ē would fit.
Ok so heres some pictures. Please go easy on my rusty innards :(
Heres a pic of the i/c
Mocking it up
All mounted up
Heres a picture of the hole placement. I canít remember if this is the final shape of the hole but pretty close.
Here it is from the front looking through the headlight hole.
Hereís a shot from the top with pipe in place. As you can tell I got a little trigger happy with the grinder, probably didnít need to be quite that big.
Another picture from the top. Make sure you either round the cut area or do what I did and put a scrap piece of coupler between the pipe and metal. Otherwise it will rub and cut a hole in your pipe.
Here it is from under neath
Where it meets the i/c.
Heres a picture of the hotside pipeing out of the car for reference.
Heres a pic of the cold side piping out of the car for reference.
Side view, this is a good picture of how the intercooler sets up against the canister in front of the condenser and rad. Also after these pics were taken the ic was drilled and tapped for an iat sensor on the cold side.
From the throttle body its just straight down. I had to remove the ducting but I havnít had any problems (115 heat this summer but I donít do track days) so if you anticipate problems youíll need to make custom ducting. Hope this helps.