TOOLS NEEDED
-Clip Tool Set OR Needle Nose Pliers/ Flat Head Screw Driver
-Ratchet
-10mm Socket
-12mm Socket
-Air Saw
-Drill
-Drill bit larger than 1/8”
-#5 Allen
- Remove Front Bumper
- Detach wiring harness from bumper support beam and unplug all connections. Move harness out of the way.
- Detach hood latch cables from bumper support beam and remove cables from both latches by removing the 2 10mm bolts that hold the latch in place.
- Remove 5 10mm bolts that hold the bumper support beam in place and remove beam.
- Discard the bracket below the hood latch using a clip tool and 10mm socket. This will no longer be needed.
- Take the foam off the front crash bar and remove the 2 10mm nuts holding the undertray support brackets. On the bottom of the crash bar is 4 clips that need to be removed as well.
- Remove crash bar by taking out the 8 12mm bolts located on the front of the crash bar.
- Undo all 4 soft pipes connecting to the intercooler.
- From here you will remove the intercooler with the plastic attached as one. There are 11 10mm bolts holding the unit in place.
- Once removed from vehicle the air dam will need to be drilled out from the backside using a drill bit roughly the same size as the rivet. Drill fast to unsure the rivet releases before spinning in place. If it does end up spinning use a small punch to break it out.
- With air dam out of the way the factory intercooler can now be removed via the 6 12mm bolts that hold it in place.
- Follow the white marks on the plastic for a reference on where to cut to make room for the RS1600 intercooler.
- Once cut and cleaned up, reinstall the plastic and everything you had just taken apart.
- The RS-1600 Intercooler can now be installed with the included hardware.
