RS_intercooler_instructions.pdf

RS4 Intercooler Installation Manual

Step 1 – Remove Headlights. Remove the two T30 Torx screws from the top of the

headlight, and the one side T30 Torx screw through the access port in the fender.

Unplug the headlight harnesses and carefully slide the headlight out from the front of the

car.

Step 2 – Remove Bumper Cover. Remove the two side grille inserts from the front

bumper. Remove the two 6mm Allen bolts from the bumper support brackets.

Remove the 10 quarter-turn fasteners from the splash shield underneath the car. Remove

the T25 Torx screws between the fender liner and bumper. Firmly push bumper in

towards the back of the car from the front. Push down on the edge of the bumper nearest

the fender well, and then pull away from the car. Next, grab the bottom of the bumper

near the fender well and pull upwards and out. After doing this on both sides t e bumper

will come straight off towards the front of the car. The headlight washer hose will need

to be disconnected, and the line crimped to prevent fluid from leaking.

Step 3 – Remove Hardware from Radiator Support. Remove four (two per side)

upper T30 bolts.

Remove eight (four per side) T45 bolts from around the bumper shocks.

Remove two (one per side) T30 bolts from each fender.

Step 4 – Remove Stock Intercooler Hose Clamps. Loosen hose clamps from upper

intercooler hoses on the side of the plastic inlet pipes (or BiPipe).

Loosen drivers side lower hose clamp from turbo outlet pipe.

Loosen passenger side lower hose clamp from turbo outlet pipe.

Step 5 – Remove Stock Intercoolers. Remove the stock intercoolers from the car with

the stock hoses attached. To do this, lift up on the intercooler and slide the intercooler

towards the front of the car. The intercooler can now be pulled from its location from the

bottom of the car. The radiator support will need to be moved in order to slide the

intercoolers out. The passenger side intercooler may require more attention due to the air

conditioning lines that run underneath it.

Step 6 – Remove Drivers Side Intercooler Bracket. Remove the drivers side

intercooler bracket by using a ¼” drill bit. Drill the heads off of the three rivets and

remove the bracket from the car.

Step 7 – Move and Remount Horns. Remove horns from either side of car. Reroute

horn wiring harness behind headlights. Drill holes in factory frame rails as shown. Be

sure to space hole away from frame rail so that the bolt and nut heads have room to

rotate.

Using existing horn hardware, bolt drivers side horn directly to from rail as shown.

Attach supplied horn bracket to passenger side frame rail, then attach horn to bracket.

Step 8 – Trim Intercooler Shrouds. Unbolt the intercooler shrouds from the stock

intercoolers. Trim the side off of the shrouds as shown by the dotted lines.