This is my old engine setup, before the 2.4L conversion. I thought I'd keep this page because I put alot of work into the intercooler install.
I finally got around to putting the intercooler into my Horizon. I had measured things and thought it'd probably fit around the TBI radiator nicely, I was very right! Fits around that radiator like a glove! The intercooler is sitting in where the condensor would go if this were an AC car (wish it were AC, but oh well). I scooted the radiator over about an inch towards the passenger side, there were actually 3 sets of holes to choose from at the top core support for the radiator to bolt to, I just used the next set over. The bottom of the radiator is hung on a couple straps of metal I screwed down. The driver's side intercooler outlet comes out right below the radiator fill neck. And the passenger side intercooler outlet is right above the radiator outlet (radiator outlet on TBI radiators is REALLY high for some reason. I had to remove the radiator hose from the radiator outlet, and shorten it about an inch, to pull that hose closer to the radiator to keep it from resting on the alternator after the move. The top radiator hose, I chopped up a Daytona T1 upper hose to make one that works. It's not pretty, but it is water tight. I used my good old 2" marine exhaust hose, just like I did on my Daytona when this intercooler was in that car. I had to make a sharp 90degree turn on the passenger side IC outlet, I used some radiator hose to make that turn, which then connects to a bit of steel pipe that Y's off for my BOV (an actual TurboXS unit). I've got an aftermarket radiator fan on the radiator, needed somthing thinner than the stock unit.
And then I also managed to squeeze in a nice cold air intake while I was at it. I had this really long flexible duct I grabbed from a 3.0 V6 van at the junkyard, and a K&N filter from one of my old motorcycles. A couple minutes fiddling around and I managed to find a decent place to route the thing to. It's inside the driver's fender, in front of the tire, directly behind the GLH foglights. (Thinkin what I'm thinkin?) Yeah, so I'll be bulding a nice enclosure around that air filter to keep tire mud/dirt/water off the filter, and I think I'll be opening some holes behind the driver's foglight (yes, lights not installed yet) to let fresh air get right at that filter.
To see the new setup, see my blog: