finalzero

Thought I would detail a simple mod I did today involving replacing the stock intercooler intake plate with a larger Zero/Sport Intercooler Intake.

I purchased the intake from Jap Performance Parts but I think there are few places that sell them (some on eBay). These make a big difference to the way the air is drawn in onto the intercooler, the Zero/Sport version in particular has a deflector fin that directs some of the air to the front of the intercooler as well as having a larger channel underneath allowing air to flow over the whole of the intercooler.

Tools Required:
Medium Sized Crosshead Screwdriver
Needle Pliers
Sharp Knife or snip pliers
2 x Zip Ties

(Optional): 5 to 8mm drill bit (for drilling metal) and electric drill, 1 x zip tie

Step 1 - Removing the old intake plate:

You may need to cut the plastic fastener holding the intake plate in as it doesn't come out easily (you will need a replacement plastic fastener for this)

Intake removed:


Remove your existing nozzles from your factory intake plate, taking care not to damage them as you will need to reattach them to the new intake. (Note: cut the ic spray pipes at the end of the nozzle so you when you secure the pipes back to the nozzles you will not be using the old stretched/worn part of the rubber pipes)

I decided to use the existing intercooler spray nozzles however you could use some windcreen/headlight washer nozzles

Attach the nozzles to the new intake and reattach to the bonnet:


Reattach the intercooler spray pipes:


Secure the pipes to the intake and the windscreen washer pipework to stop them fouling anywhere in the engine:


Optional: I was going to do this but will save it for a later day. You could drill a small hole on the front part of the intake channel and then secure the pipework that is hanging below the intake to stop it from getting caught underneath the sharp edge of the intake.

The finished result:


Very simple mod but effective. I took the car out for a few blasts and did notice an improvement, the car did not seem as laggy after being driven hard for a while so the mod is obviously directing more cold air to the intercooler - great!

Bob Rawle

Since you have no seal between the tray and intercooler you will not be getting more air thro', the gap must be sealed. Watch out in Summer !!

A splitter in the std fitment works very well and retains the seal.

best regards

bob

finalzero

What would you recommend to seal the gap? I have been looking into sorting this out at the weekend but wasn't sure what to use (and something that can withstand the engine heat). Would the rubber strip from a door/boot work?

finalzero

Found the perfect item on eBay no less Oven door seal gasket, found the exactly the right type i.e with a flat shape gasket with a split in the middle to push onto the edge of the Zero/Sport intake panel, all for £6.50 including postage.

Should withstand the head very easily.