Engine Start Up Attempt 2 and Intercooler Installation

One thing that needed doing (not essential for running of the engine) was the throttle cable problem: it didn't reach the throttle body! I could fit a longer throttle cable or adjust my current mount somehow. I found I could turn this upside down, and had to make a upside down mount for it, then the cable reached the throttle body fine:

So the engine still didn't start. The ECU has power, it's turning over, its got spark, the timing is correct, its got fuel. The only thing left to go on (as far as I can see) is the intercooler and ABV block. As this is a supercharged system, the engine runs under vacuum, so the supercharger does need to be directly connected to the intake for it to run. Without it, its basically running on a massive vacuum loss. So hopefully with the installation of the front mounted intercooler, I'd have it up and running.

Firstly I thought I'd best put the exhaust manifold back on:

I then had to sort that long overdue ABV block out. The ingenius idea of using a broom handle came up, and the problem was solved!

At first I mounted the intercooler brackets in the centre of the bumper mounts, but this would make the intercooler too low and the in/outlet would go straight into the chassis rail which I cannot cut. I raised it a bit more and it fitted just right under the curve of the bonnet brace bar where it curves out to accomodate the grille. This aligns the in/outlet of the intercooler above the chassis rail, so I could curve the pipes into the engine bay. I also test fitted the bumper over it, and found the extended intercooler bracket was also helpful in adding more leverage to mount the bumper onto.

Here is some of the modifications I made to the bumper brackets to accomodate the intercooler and piping:

MY first plan of action was to have 2.5" [64mm] (the size of the intercooler in/outlet) to 2" [51mm] silicone reducers out the in/outlet of the intercooler, then go into metal 90degree bends and into the engine bay. I noticed the bends would come out right into the wheel arch though, my intercooler was too big and my piping too long too! So I had to change the plan a bit later.

I needed a slight bend in the supercharger outlet side to reach the intercooler. The inlet side requires raising of the pipe and down into the inlet, I got a tube already made which came with my FMIC package, although it was a 90degree bend short which I can make up with one of my own, this tube got the piping right down to the inside of the engine bay, so it would need to be extended to the intercooler outlet to complete too:

This is basically how the system would be put together:

So I started by cutting out holes for the intercooler pipes to go through, I tested the 90degree silcone bends and needed to trim them down a bit to fit, but got there in the end:

The fuel filter was in the way so I had to move this, and the bracket to continue with the piping for the supercharger outlet side:

I got 2 45degree silicone bends for the supercharger outlet side, and cut them down and this seemed to do for this part, they are held on with 2"(51mm) aluminium pipes inside, and Jubilee clips:

From the same 2 bits that I use inside the supercharger out pipe I used the 90degree aluminium bend on top of the intake piping side to complete this part of the circuit:

and finally to complete the whole piping, an 2.5" (73mm) polished stainless steel pipe connected the bottom of the above pipe using a 2.5" - 2" reducer, and straight into the 2.5" silicone 90degree outlet of the intercooler.

Just some jubilee clips to finish the job off too:

With that done, the engine build should be complete, so once again, engine starting time...