How to fit a Front Mounted InterCooler to a Facelifted Vectra 1.9 CDTi SRi Nav
Following on from this thread I decided to give you a summary of what I finally did.
First I bought a Front Mounted InterCooler off eBay (Search for item - 220144653681)
The Dimentions of the intercooler are as follows...
- 2.5" inlet/outlet
- Core Length : 21"
- Core Height: 6"
- Core Thickness: 2.5"
- End to End" Length: 28"
In the advert it states that the core thickness is 2 3/4" but its not... its actually 2.5" (which is in our favour). Also it states that the end to end length is 28.5" but its not.. its 28" (which again is in our favour).
Secondly, as the new FMIC would be blocking the radiator at the bottom, I decided to cut out the blanking plate behind the grill to allow more air through...
Then comes the fitting...
The mounting holes in the top of this FMIC are 8mm in diameter and I purchased some 8mm rods which simply screwed into the holes. I then got some 'L' brackets and used a 6mm bolt through the crash bar to mount the 'L' bracket to the bar itself. Then I attached the 8mm rod through the 'L' bracket and cut it to size. Then fitted it all with 8mm bolts which also have nylon inserts to stop them undoing.
The intercooler is as far back as it can possibly go without touching the heat exchanger behind. You will need as much space for the bumper to fit, so as you can see above, its really tight, but fits perfectly.
Ok... On the passenger side you will need the following
1 x Samco Xtreme 90 Degree 63mm to 57mm Reducer Silicon Hose
1 x 60-80mm Stainless Hose Clip
1 x 50-70mm Stainless Hose Clip
1 x 2:1/4" Alloy Hose Joiner
1 x Samco 90 Degree 57mm Hose Elbow
2 x 50-70mm Stainless Hose Clips
On the drivers side you will need
1 x Samco 90 Degree 63mm to 51mm Reducer Silicon Hose
1 x 60-80mm Stainless Steel Hose Clip
1 x 2" Diameter - 3 Inch long Alloy Joiner Hose
1 x Samco 90 Degree 51mm to 45mm Reducer Silicon Hose
3 x 40-60mm Stainless Steel Hose Clips
Getting the bumper back on in one piece is almost impossible, so I had to make some alterations to the bottom grill.
Firstly you will need to cut off all the nobbles
and ensure that the 'Air Flow Meter' is relocated. I stuck it up in the top right hand side of the grill...
BUT, it does all go back on so enjoy !!