peteluc

Bought an sti v5/6 intercooler for my classic wagon... Doesnt seem to physically fit but has anyone made any mods to make it?

Looks like bulk head will have to be modified (boschometer) at least..

555tom

iTrader: (2)

You will need to cut the lip off the intercooler, and some also cut the throttle body down slightly.

Bash the rear engine mount down with a large hammer.

Helps to remove the 2 bolts for vacuum pipe for the servo, on the back of the bulkhead.

You will also need to buy the following type of hose if its going onto a 1996 or earlier wagon...

http://cgi.ebay.co.uk/ws/eBayISAPI.d...=STRK:MEWAX:IT

And finally blank off the version 5/6 re circ valve..

Hope this helps, i did it last week and made ALOT off difference!

555tom

iTrader: (2)

Also helps if you cut down the hose between the throttle body and the intercooler!

peteluc

Ahh so it can be done!, spot on advice thank you very much!!!

tom i have the original hoses that came off the old car they should fit right?

Does it matter if the recirc dump valve is blocked off and no dump valve is ran at all?

peteluc

What lip did you take off the intercooler tom?

555tom

iTrader: (2)

Original hoses wont fit im afraid, if your on about the plastic type. Ideally you need to purchase the hoses in the link i gave you or the samco version and then they need cutting down where it fits to the intercooler. It will become clear when you buy them and fit them!

And you dont have to run a dump or re circ valve, but it can damage your turbo after time, if you look in my pic you can see mine has been blocked off.

Also heres a picture of the lip cut off on the intercooler...Its just the raised part where the hose joins to, this is to stop is popping off.

I also removed all the standard intercooler brackets, as they dont fit anyway, once you fit the cooler, its wont be going anywere...there pretty solid once in!

GC8

Possible but pointless. A 2004> New Age STI intercooler would provide a worthwhile benefit, but itd be even harder.

555tom

iTrader: (2)

Id deffo not recommend fitting anything bigger than the sti5/6.

And its 100% not pointless aslong as you have the correct under tray fitted, as i said before mine used to die out higher up the rev range, but now pulls alot harder all the way through the rev range...

peteluc

Hi Tom
Thanks again great info! and I agree it's not pointless ive had the standard intercooler and the sti one next to it and its a fair size larger (and is obviously larger due to the mods needed to make it fit!).

When I purchased my sti one it came with samcos on it which I think will fit ok. and ive got the larger undertray for the bonnet.

555tom

iTrader: (2)

If your on about the red samco which comes standard with the sti5/6 it wont reach your turbo! I made the same mistake!