Charge Cooler install step by step, Lots of pics

[Steve-O 2009]

Heres my Charge cooler install for a Rev2. Most of the info I got was from Toxos guide so For details on part numbers needed etc, see Toxo's thread -

http://www.imoc.co.uk/forums/viewtop...103914&start=0

-- Update --

After fitting the core I found for the rev2 install you only need the ST185 Sock and ST205 Throttle cable mount. You do NOT need the throttle body stay or engine hook as these are not needed for the Rev2 install

First I got all the stuff needed



Then I wrapped tape half way down the hose so I knew which end was which when I ran it



I found that I just had to get the front of the car in the air and that was enough to run the pipe from the front to back.



I then mounted my Horns here



I decided to run my pipes from the front of the car to the back and started here



Around the steering area like this



Then under the handbrake cable mount



BUT I decided to change that as this means both pipes are touching Hot radiator pipes. I decided to nominate one hose to be the "Hot" hose, this one will carry hot water from the charge cooler and will be the hose that will be in contact most with the cars radiator hose / pipe. I then attempted to keep the other hose away from any heat. This is what I changed it to, might not make much of a difference but who knows :)



I then went over this mount (Note that the foam bits arent their now, I used thin foam strips now just incase the pipe vibrated and ended up wearing through probably wouldnt but I wanted to be safe :). Longer bolts are need here to bolt the trays on as stated in Toxos thread but I had to cut them in half as they were too long. Maybe you could lower that mount with washers to get the pipes under?



Now just cable tie the pipes untill your at the rear (not far) I added foam here to seperate my Hot and cold pipe again might not make a difference realy



And thats it, your at the back of the car :). I just slotted the pipe through a gap in the undertray near the engine (As seen in the above pic) and then up into the engine bay.

Get out and get back to the front end. Unbolt the AC Sensor, Cut the AC Sensor bracket off and cut off the bracket that holds the wire above it (above the AC pipe). Now start making some Brackets. You will noticed the fiat rad holes line up perfect with the old horn bolt holes :). Toxos thread has dimensions on making some but me and my dad just got some bar and started shaping it untill we get something we were happy with (see pic below) :)


Once thats done connect it all up. I ran my pipes this way and had no problems with it catching my border bumper or anything :) May cause problems with Fog lights so you might have to work your own route out but its not hard :). Oh I used 90 Degree Fish pond connectors and straight fishpond connectors as they only cost £1.60 for the 90 Degree and 60p for straight :)



Now sit back and admire your work






Now Get back under, pull the excess pipe through and cable tie the pipes where ever you can to secure them and put your under trays back on.

I mounted the AC Sensor here on the Fiats Radiator fan switch :) (I just drilled the plastic connector block) :D



I will be doing the pump next weekend so will add pics of that :)

If theres any spelling mistakes etc just ignore them, Im tired and my fingers hurt from doing this install lol


Part 2 Switch Install

First I ran some 2 core wire from the boot and into the engine bay (speaker wire will do). I used 2 core to power an LED and for the switch.




Then I ran the wire from the engine bay into the car behind the drivers seat (pull the carpet back from behind your seat to see the grommet)




Tuck the wire under your door trim and run it to your dash




Ignore the mess of wires, I know what they are :). The one you want to look at is the Blue and Brown wire. I connected the brown to my switch and the blue to the Positive of the LED. I then Earthed the LED to an earth and connected the switch to a Positive feed.




Switch and LED Done :)




I then fed the pump wire and power wire through this grommet and into the engine bay. Mark which wire it which so you dont forget :).




Picture is a little blury but you should get the idea. Relay is mounted near the ECU, Orange wire is Earth, Black wire is connected to the pumps + side (yellow wire with white tape on it), Red Wire is connected to a 30 amp fuse holder and then to the Positive feed from engine bay (yellow wire), the brown wire is the switch wire. I then wired the blue wire (the LED wire) to the pumps positive feed.




I ran the Positive feed into the fuse box here, you can run it up with the standard wires to make the install nice and tidy. I made my own power connector eyelet with a thick washer as the others looked a little too thin




All Done, Switch off




Switch On, LED comes on so I know the pump will be getting power :D. If the Fuse goes or the relay fails then the LED wont come on as its wired to the Pumps positive feed, if the pump isnt getting power then the LED wont get power :) . I went to maplins and got a 5mm Red LED, 680 ohm resistor and a LED holder, came to about 85p :)




Got some bolts for the Pump so that will be going on next, hopefully after work this week sometime :D

Part 3 - Pump installation

Get the back of the car right up in the air as far and safely as possible (close :o )




Now get your pump and bolt it on here. I modified / drilled my pump bracket so I could raise it up a little bit more as you can see in the pic. When you put the pump on the pumps in and out ends will face downwards so undo the pump mount / strap and rotate it so it looks like mine in the pic then tighten it again. Earth the pump to one of the pumps bolts.




Now boil the kettle, put boiling water into a cup and get the fairy liquid and get under the car. Cut your Pump pipe near the pump so it reaches the pump with a little bit of play. Put the ends of the pipe into the boiling water and lube the pump connectors with fairy liquid. Wait 3 mins and the 19mm pipe should slip right on. The Left is Inlet (Charge cooler pipe goes here) the Right is outlet (Radiator pipe goes here). Now run your pumps Positive wire down to the pump and solder it on.




Looks low where it is but the Flexi is still lower




Part 4 - Core Installation. Unfortunatly due to the rain, wind and cold I couldnt be arsed taking photos, I just wanted it done but I got the main ones :)

First remove your X Brace and your IC Pipe work



Now Remove your throttle body mount etc and you will end up with this. The Rev2 Does NOT need a Throttle body mount as theres already another one that holds it rock solid.



Now rest your Charge cooler inplace and you will then see what needs modified on the car and on the core.

I had to bend this boost / vacuum line and this breather pipe or what ever it is. Very Easy to do by hand and the mount for it bends nice and easy so problems here :)




I Then Cut both the Mounting points off the Charge cooler that face the Air filter / Passenger side of the car as again these catch / get in the way.

Now you need to bend the water inlet and outlet pipe. Get somethign that fits perfectly in the hole and bend it untill it will clear the MR2's coolant pipe. (might not have to bend the outlet pipe but I did for some reason but cant remember)

Now put the Throttle Sock onto the core and line it up and everything should clear.

You will notice that the Cores Turbo intake pipe doesnt line up. Get something that fits perfectly in and give it a little bend. I ended up tapping mine with a hammer but be carefull as it can bend easy as I found out :(




Keep going untill you end up with something like this or better




Run your coolant pipes to the core area and cut the excess off. I then added 90 Degree elbows as seen here



Now cut 2 small bits of pipe that can run from the core to the 90 degree elbows. Remove the core and put your 2x small pipes into boiling water and lube the cores in / outlet pipes up and push the pipes on (easier doing this now than when on the car!!) Now apply your Heatsheild material if you bought some as its almost time to put the core on. :)




Now this is the tricky bit. if you get stuck leave it and come back to it with a clear mind, I did and it helped :) It Might sound sad but I was laying in bed thinking of how to get it on and this is what I thought about / did -

-Lube the Cores Turbo Intake pipe up and slide the rubber hose right up the pipe (the hose the clamps onto the core and turbo)
-Put the bolts and accelerator bracket onto the sock
-Put the Sock on to the core on an angle and clamp it on so it doesnt pop off (so when its lined upto the bolt holes the core is on a 45 Degree angle, this keeps it away from the turbo and gives you more movement to help get the bolts in and allows a bit better access to the bottom bolts)
-Line the socks bolts up and tighten. I found it easier to tighten them by finger first
-Loosen the clamp a little and rotate the core flat
-Bolt the Core down with its remaining mount
-Slide the Intake hose down from the cores intake pipe and onto the turbo


Now connect your water pipes up. Pipe closest to the turbo is the inlet (cold water from radiator) and the one below the coolant filler cap is the outlet (warm water going to the pump and then radiator).




If you have a Swirl / Overflow pot then mount it here. You will need to make a little bracket (I bolted it to the bolt going into the engine lid catch)




Now your ready to add the coolant What we did was open the bleed pipe on the front and fill the system with coolant untill it would take no more, closed bleed pipe and turned the pump on and kept on adding coolant. Then we got 2 bottles, one empty and one with coolant in. Turned the pump off, Opened the bleed pipe at the front and put the pipe low down into the empty bottle. While I was filling the bottle at the front my dad was topping the core up with coolant. When he emptied the coolant out of that bottle we switched bottles over so I had the empty one and he had the one I had been filling up. We kept on doing this untill no bubbles were coming out of the bleed pipe.

My coolant moving around -

http://img21.imageshack.us/img21/1975/10102009078.mp4
http://img195.imageshack.us/img195/1856/10102009076.mp4

When all done you should have something like this




Now put your X Brace back on and admire your hard work :D










I need to read through this and check for mistakes and make sure I have linked to the right images but that can wait untill tomorrow :)

[Andre]

cracking job so far m8 i have still yet to sort mine out so i will be keeping an eye on your progress steve thats a good how 2 guide upto now

[snowtigger]

me and greg where talking about doing an install guide for the mk1.5 setup as well this is a very interesting post carry on with the good work.

[Shadeh]

me and greg where talking about doing an install guide for the mk1.5 setup as well this is a very interesting post carry on with the good work.

I agree great work, and a mk 1.5 install would be great too!

[Steve-O 2009]

Thanks all

I think guides with pictures in are alot better then guides with loads of writing. You just have to look at the pic realy and you get the idea of what to do :)

Oh and if I can do this, Anyone can!! This is my first car realy that I have actually modified in the tuning department (maybe because its only my 2nd car :) ). The only real modifications that I have ever done in the past is put alloy wheels on my Merc 190E and fitting a flip out DVD head unit to it LOL. Im not a mechanic, I just go out and have a go myself and if I can do it then great its something else I can do :)

[BSM]

If anyone needs further info or pics of Toxo's car or of the article he wrote drop me a pm, John is a personal friend of mine and I've scraped my knuckles many times working on his car.........

[Steve-O 2009]

Switch install pics up on the first post :)

[Steve-O 2009]

All Finished now :D :D I will post more pics / info up tomorrow but for now heres the final product :D

[Steve-O 2009]

first post updated

[moohahaitz131]

i dont understand where the bov is mounted with the cc set up? can someone explain please.