POWERSTROKE INTERCOOLER INSTALL
Pic of the front end prior to the installation
Pic with front clip taken off
New Powerstroke Intercooler
Comparing stock intercooler with new powerstoke intercooler, its just a little bigger
Intercooler pipe placement
Intercooler tube entrance through core support
Show's where the plastic had to be cut on each side to fit the pipes
Pic of intercooler through the grille with front end attached again
ADDITIONAL INFO
To cut the holes in the core support, due to certain bends in the metal I found it a lot easier to use a plasma cutter than a sawzall. If you don't have access to a plasma cutter then a sawzall will work, but it will be quite a bit harder and not as clean of a cut. You are going to have to get intercooler hoses of some sort and get the T-bolt clamps, I made the mistake of not getting them and it blew the hose right off the intercooler. They say the intercooler has both a 3" inlet and outlet, but there is a sort of a ridge on the end so 3" intercooler hose will work you just need to force it on and i put dish washing detergent on the intercooler itself so the hose slides on. The AC line will need to be relocated, if you give it a slight bend upward and lift it over the one that it is currently under and it should give you clearence for the intercooler tubes to pass through. Now, people say that you have to get rid of your high beams, if you are very careful you can still keep them, but the cut will be very close. The hardest part of this install to be honest was the cutting. My car was original and I did not want to cut into such a beautiful car, cause you have to cut the plastic headlight bezels, the header panel and the core support. I suggest you do what I did and purchase an extra header panel, core support, and headlight bezels and use those to cut in case you want to put your car back to orginal. Other than that it was pretty basic, I can talk you through any of it if you decide to do this install and require assistance please feel free to email me at intercooledgn@aol.com.
