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Transfer

Major VersionM

by Rich Harris

Introduction

In this installation guide we have provided step by step instructions to remove the OEM Intercooler, setup, and install the 27WON Performance Intercooler.

Advisory:

  • Working under the vehicle requires a safe and sturdy location for the vehicle to sit on jackstands.
  • The engine bay will be hot after recent vehicle operation. Allow the vehicle to cool or use a fan to cool the engine bay before working on the vehicle.
  • Removing the bumper is very difficult to do by yourself and can result in scratches to the paint or headlights. We strongly encourage using a friend's help during bumper removal and installation.
  • Trimming the rubber OEM intercooler shrouds is necessary for 27WON Intercooler fitment. This is easy and can be done with scissors.
  1. First and foremost; THANK YOU for becoming a part of the 27WON Family.  We hope to REDEFINE your experience of the aftermarket with the highest level Parts, Customer Service, Packaging, & Support
    • First and foremost; THANK YOU for becoming a part of the 27WON Family. We hope to REDEFINE your experience of the aftermarket with the highest level Parts, Customer Service, Packaging, & Support

  2. If you purchased your 27WON Front Mount Intercooler with Silicone Boost Tubes then you'll want to review the installation instructions for those before proceeding
  3. Begin by freeing the OEM weatherstripping from the upper radiator panel There are five push clips, roughly marked with red circles in the image, that are removed by pulling upwards on the weatherstripping Free the large rubber tab (orange circle) from the corner of the OEM intake duct by pulling upwards
    • Begin by freeing the OEM weatherstripping from the upper radiator panel

    • There are five push clips, roughly marked with red circles in the image, that are removed by pulling upwards on the weatherstripping

    • Free the large rubber tab (orange circle) from the corner of the OEM intake duct by pulling upwards

  4. Remove the eleven push clips that attach the radiator cooling panel to the vehicle using a flathead screwdriver or push clip removal tool Remove the upper radiator panel from the vehicle Starting on the driver's side, remove the five push clips that connect the hood weather stripping to the bumper using a flathead screwdriver or trim removal tool
    • Remove the eleven push clips that attach the radiator cooling panel to the vehicle using a flathead screwdriver or push clip removal tool

    • Remove the upper radiator panel from the vehicle

    • Starting on the driver's side, remove the five push clips that connect the hood weather stripping to the bumper using a flathead screwdriver or trim removal tool

    • There are three small push clips, one medium push clip, and one large push clip. Note their positions for reinstallation

    • The small push clips can be difficult to remove with just a screwdriver. We recommend an interior trim removal tools used as shown in image 3

    • Remove the similar five clips on the passenger side of the vehicle

  5. Remove the hood weather stripping and set it aside Raise the vehicle and support with jackstands in the OE recommended locations Look into the driver's side fender, in front of the front tire. Remove the four phillips head screws that attach the bumper to the fender liner
    • Remove the hood weather stripping and set it aside

    • Raise the vehicle and support with jackstands in the OE recommended locations

    • Look into the driver's side fender, in front of the front tire. Remove the four phillips head screws that attach the bumper to the fender liner

    • The screws can be difficult to remove due to the tire being in the way. You can turn the wheel or use an offset screwdriver like shown in the third image for easier access

    • Remove the similar screws on the passenger side of the vehicle

  6. Locate the engine undertray for later access to the hot side boost tube Remove the two Phillips head screws using a Phillips screwdriver
    • Locate the engine undertray for later access to the hot side boost tube

    • Remove the two Phillips head screws using a Phillips screwdriver

    • Remove the six quarter turn screws using a large Flathead screwdriver

    • Slide the metal section rearward and remove it from the vehicle

    • The metal section of the undertray can be sharp. Use caution when handling it

  7. For clarity, the image of the underside of the car was split into two images. Both images show the center push clips From the underside of the front bumper, remove:
    • For clarity, the image of the underside of the car was split into two images. Both images show the center push clips

    • From the underside of the front bumper, remove:

    • Four 10mm bolts using a 10mm socket and ratchet (shown with two circles and two arrows)

    • Two 5mm Allen bolts using a 5mm Allen key or socket

    • Nine large push clips using a flathead screwdriver or push clip removal tool (shown with 7 circles and two arrows)

    • Three small push clips using a flathead screwdriver or push clip removal tool

  8. Now is a good time to apply tape to protect your paint from scratches during bumper removal and install Apply masking or painters tape around the seams where the bumper meets the body of the car
    • Now is a good time to apply tape to protect your paint from scratches during bumper removal and install

    • Apply masking or painters tape around the seams where the bumper meets the body of the car

    • We did not use protective tape during the rest of our installation for clarity of the installation instructions

  9. Using a small screwdriver, push down on the two tabs to release the upper headlight trim from the headlight on the driver's side These tabs do not require very much pressure and can break if too much pressure is used. Pull outward slighly on the trim and you will feel the "pop" as each clip releases
    • Using a small screwdriver, push down on the two tabs to release the upper headlight trim from the headlight on the driver's side

    • These tabs do not require very much pressure and can break if too much pressure is used. Pull outward slighly on the trim and you will feel the "pop" as each clip releases

    • The upper headlight trim will not be removed, it will only move outward as shown in image 2

    • Repeat these steps on the passenger side

  10. Starting at the corner of the bumper, pull outward until the corner pops free from the fender The first time this is done can require a decent amount of force Keep pulling outward on the bumper and use a plastic interior trim tool to release the bumper from the three retaining clips by pushing on the retaining clips
    • Starting at the corner of the bumper, pull outward until the corner pops free from the fender

    • The first time this is done can require a decent amount of force

    • Keep pulling outward on the bumper and use a plastic interior trim tool to release the bumper from the three retaining clips by pushing on the retaining clips

    • The third image shows what you are looking for to push on. Take your time and take care to not damage the vehicle

    • Repeat these steps on the passenger side

  11. Moving along the headlight, keep pulling outward slightly Using a plastic interior trim removal tool, lift up the two tabs to release them The second image shows what you are looking for to lift upwards. Take your time and take care to not damage the vehicle
    • Moving along the headlight, keep pulling outward slightly

    • Using a plastic interior trim removal tool, lift up the two tabs to release them

    • The second image shows what you are looking for to lift upwards. Take your time and take care to not damage the vehicle

    • This side of the bumper will now be free from the vehicle. We recommend having a friend hold this side of the bumper while the other side is completed

    • Repeat these steps on the passenger side

  12. The bumper will now only be held on by the fog light wiring Pull the bumper forward and locate the wiring going to the fog light on the driver's side Reach between the bumper and the rest of the vehicle. Unplug the fog light by squeezing the top  and bottom of the plug
    • The bumper will now only be held on by the fog light wiring

    • Pull the bumper forward and locate the wiring going to the fog light on the driver's side

    • Reach between the bumper and the rest of the vehicle. Unplug the fog light by squeezing the top and bottom of the plug

    • Repeat the prior two steps to unplug the passenger side fog light

    • Remove the front bumper from the vehicle and place out of the way where it cannot get scratched or damaged

  13. Locate the OEM hot side boost tube. It's in the general area of the red arrow connecting the intercooler and turbocharger Loosen the clamp that attaches the OEM hot side boost tube to the intercooler using a 10mm socket and ratchet Slide this clamp toward the center of the OEM boost tube and out of the way
    • Locate the OEM hot side boost tube. It's in the general area of the red arrow connecting the intercooler and turbocharger

    • Loosen the clamp that attaches the OEM hot side boost tube to the intercooler using a 10mm socket and ratchet

    • Slide this clamp toward the center of the OEM boost tube and out of the way

    • Pull the OEM boost tube free from the intercooler

    • The OEM hot side boost tube is shown completely removed for clarity. Only one side needs to be removed for 27WON Intercooler installation

  14. Remove the 10mm bolt from the OEM hot side mounting bracket on the passenger side of the vehicle using a 10mm socket and ratchet Lift the bracket free from the vehicle
    • Remove the 10mm bolt from the OEM hot side mounting bracket on the passenger side of the vehicle using a 10mm socket and ratchet

    • Lift the bracket free from the vehicle

    • Remove the bolt from the OEM hot side pipe using a 10mm socket and ratchet

    • Remove the 10mm bolt from the OEM cold side mounting bracket on the driver's side of the vehicle using a 10mm socket and ratchet

    • Lift the bracket free from the vehicle

  15. Remove the two 12mm bolts that attach the OEM intercooler to the OEM cold pipe using a 12mm socket and ratchet The OEM rubber intercooler "shrouds" will be hanging in front of the intercooler. Simply fold them out of the way when removing the intercooler
    • Remove the two 12mm bolts that attach the OEM intercooler to the OEM cold pipe using a 12mm socket and ratchet

    • The OEM rubber intercooler "shrouds" will be hanging in front of the intercooler. Simply fold them out of the way when removing the intercooler

    • The intercooler is now free to be removed. Lift upwards to free it from the lower mounts and remove it from the vehicle

  16. The OEM intercooler shrouds must be trimmed to fit the much larger 27WON intercooler The section in orange is discarded after trimming Locate the area in yellow on the driver's side shroud
    • The OEM intercooler shrouds must be trimmed to fit the much larger 27WON intercooler

    • The section in orange is discarded after trimming

    • Locate the area in yellow on the driver's side shroud

    • Cut along the green line

    • The remaining shroud will sit on top of the 27WON intercooler slightly. This is intentional to force good airflow through the intercooler and radiator

  17. The OEM intercooler shrouds must be trimmed to fit the much larger 27WON intercooler The section in orange is discarded after trimming Locate the area in yellow on the passenger's side shroud
    • The OEM intercooler shrouds must be trimmed to fit the much larger 27WON intercooler

    • The section in orange is discarded after trimming

    • Locate the area in yellow on the passenger's side shroud

    • Cut along the green lines as shown

    • The remaining shroud will sit on top of the 27WON intercooler slightly. This is intentional to force good airflow through the intercooler and radiator

  18. Remove the OEM O-ring from the cold side endtank of the OEM intercooler by pulling it free using the small tab shown with the red arrow Install this O-ring into the cold side endtank of the 27WON intercooler. Ensure the tab is aligned with the cutout groove in the 27WON endtank
    • Remove the OEM O-ring from the cold side endtank of the OEM intercooler by pulling it free using the small tab shown with the red arrow

    • Install this O-ring into the cold side endtank of the 27WON intercooler. Ensure the tab is aligned with the cutout groove in the 27WON endtank

  19. Remove the metal sleeve from the rubber grommet on the OEM hot pipe Squeeze the rubber grommet and slide it out of the OEM hot pipe Repeat the previous two steps in reverse to install the rubber grommet in the hot side of the 27WON intercooler
    • Remove the metal sleeve from the rubber grommet on the OEM hot pipe

    • Squeeze the rubber grommet and slide it out of the OEM hot pipe

    • Repeat the previous two steps in reverse to install the rubber grommet in the hot side of the 27WON intercooler

  20. Locate the supplied weather stripping Locate the top edge of the 27WON Intercooler. It sticks out slightly in front of the fins of the intercooler
    • Locate the supplied weather stripping

    • Locate the top edge of the 27WON Intercooler. It sticks out slightly in front of the fins of the intercooler

    • Attach the weather stripping to the top edge of the 27WON FMIC as shown. It can be pushed on with a little pressure

    • You want the round portion of the weatherstripping facing upwards to seal against the OEM crashbar to ensure good airflow through the intercooler

  21. Locate the OEM hot side intercooler bracket. Look for the R stamped into the bracket Remove the rubber bushing from the hot side intercooler bracket. It can be pushed free from the bracket
    • Locate the OEM hot side intercooler bracket. Look for the R stamped into the bracket

    • Remove the rubber bushing from the hot side intercooler bracket. It can be pushed free from the bracket

    • Install the rubber bushing into the supplied 27WON hot side intercooler bracket. It can be pushed into position, similar to how it was removed

    • A prototype 27WON bracket is shown. Yours may differ in appearance/color slightly

  22. This step is for European cars only. Skip this step if your car does not have the crash bumper shown EU cars have an extra black crash bar shown by the red arrow
    • This step is for European cars only. Skip this step if your car does not have the crash bumper shown

    • EU cars have an extra black crash bar shown by the red arrow

    • This black crash bar holds 3 parking sensors circled in green

    • Undo the 6 black clips for parking sensors harness from the bar shown by orange arrows

    • Remove the crash bar. There will be multiple bolts holding it on

    • Shown is the under side of the crash bar. In the center is a small tab, yellow arrow. Bend back the tab as shown to make room for the 27WON FMIC

  23. Start by locating the two supplied M10x1.5x30mm bolts. Have these nearby when lifting the intercooler into the vehicle These bolts will attach the intercooler though the lower OEM rubber grommets. The bolts will pass through these mounts as shown for reference in image 1 Lift the 27WON intercooler into position. Secure the driver's side by threading one of the supplied M10 bolts a few turns into the intercooler
    • Start by locating the two supplied M10x1.5x30mm bolts. Have these nearby when lifting the intercooler into the vehicle

    • These bolts will attach the intercooler though the lower OEM rubber grommets. The bolts will pass through these mounts as shown for reference in image 1

    • Lift the 27WON intercooler into position. Secure the driver's side by threading one of the supplied M10 bolts a few turns into the intercooler

    • While holding the intercooler in place, slide the OEM hot side boost tube over the end of the hot side endtank of the 27WON intercooler

    • The vehicle that was used for installation instructions had 27WON boost tubes installed at the same time. Installation with OEM boost tubes is identical

  24. Secure the passenger's side by threading  the other supplied M10 bolt a few turns into the intercooler Attach the rear hot side mounting location to the vehicle using the OEM bolt removed earlier. Only thread the bolt in a few turns for now Attach the cold side endtank to the OEM cold pipe using the two supplied M8x1.25x25mm bolts. Tighten the bolts evenly so the flanges come together square
    • Secure the passenger's side by threading the other supplied M10 bolt a few turns into the intercooler

    • Attach the rear hot side mounting location to the vehicle using the OEM bolt removed earlier. Only thread the bolt in a few turns for now

    • Attach the cold side endtank to the OEM cold pipe using the two supplied M8x1.25x25mm bolts. Tighten the bolts evenly so the flanges come together square

    • Torque the M8 bolts to 18-22ft-lbs using a 13mm socket and ratchet

  25. Tighten the bolt at the rear hot side mounting location until snug using a 10mm wrench Tighten the two M10 bolts through the bottom OEM mounting grommets until snug using a 15mm socket and ratchet Install the OEM cold side bracket onto the 27WON intercooler. The rubber grommet fits over the peg on the endtank
    • Tighten the bolt at the rear hot side mounting location until snug using a 10mm wrench

    • Tighten the two M10 bolts through the bottom OEM mounting grommets until snug using a 15mm socket and ratchet

    • Install the OEM cold side bracket onto the 27WON intercooler. The rubber grommet fits over the peg on the endtank

    • Secure the OEM cold side bracket using the OEM hardware removed earlier. Tighten until snug using a 10mm socket and ratchet

  26. Install the 27WON hot side bracket onto the 27WON intercooler. The rubber grommet fits over the peg on the endtank Secure the 27WON hot side bracket using the OEM hardware removed earlier. Tighten until snug using a 10mm socket and ratchet
    • Install the 27WON hot side bracket onto the 27WON intercooler. The rubber grommet fits over the peg on the endtank

    • Secure the 27WON hot side bracket using the OEM hardware removed earlier. Tighten until snug using a 10mm socket and ratchet

    • Secure the hot side boost tube to the 27WON intercooler using the OEM clamp. Tighten until the boost tube buldges slightly using a 10mm wrench or socket and ratchet

    • 27WON T-bolt clamp shown as they are used with the 27WON boost tubes. OEM similar

  27. This step is for European cars only. Skip this step if your car does not have the crash bumper shown
    • This step is for European cars only. Skip this step if your car does not have the crash bumper shown

    • With the FMIC installed, reinstall the black crash bar removed earlier

    • Reinstall the 6 black sensor harness clips back into the black crash bar

    • Make sure the parking sensors are back in position

  28. We strongly recommend using a friend to help you with bumper reinstall. This makes it much easier to prevent damage to the paint of the vehicle Lift the bumper close to the front of the vehicle
    • We strongly recommend using a friend to help you with bumper reinstall. This makes it much easier to prevent damage to the paint of the vehicle

    • Lift the bumper close to the front of the vehicle

    • Plug in fog lights on both sides of the car by reaching between the bumper and rest of the vehicle as you did in step 11. The plugs will click audibly when fully plugged in

  29. Start by lifting the bottom edge of the bumper into position first Then lift the top of the bumper upwards and inwards to place it on top of the upper bumper support
    • Start by lifting the bottom edge of the bumper into position first

    • Then lift the top of the bumper upwards and inwards to place it on top of the upper bumper support

    • Upper bumper support labeled with yellow arrows

    • The corners of the bumper can easily get caught during this process. Ensure they do not get caught to prevent damaging your paint

    • Starting on the driver's side, work your way from the inner corner (left in image) of the headlight to the corner of the bumper and connect the five clips removed in steps 9 and 10

    • Leave the corner of the bumper under the marker light free for now as shown

    • Repeat for the other side of the vehicle

  30. It is common for the fender liner to end up outside of the rear edge of the bumper and front lip as shown in image 1 Push the fender liner so all parts of it end up inside the rear edge of the bumper/front lip. This is shown completed in image 2
    • It is common for the fender liner to end up outside of the rear edge of the bumper and front lip as shown in image 1

    • Push the fender liner so all parts of it end up inside the rear edge of the bumper/front lip. This is shown completed in image 2

    • You can then secure the corner of the bumper below the marker light

    • Repeat this step on the other side of the vehicle

  31. For clarity, the image of the underside of the car was split into two images. Both images show the center push clips From the underside of the front bumper, reinstall:
    • For clarity, the image of the underside of the car was split into two images. Both images show the center push clips

    • From the underside of the front bumper, reinstall:

    • Three small push clips

    • Seven large push clips

    • You will have two large push clips leftover after install

    • Two 5mm Allen bolts using a 5mm Allen key or socket. Tighten until snug

    • Four 10mm bolts using a 10mm socket and ratchet. Tighten until snug

  32. Lift the metal section of the undertray into position The front edge of the metal will fit over the top of the rear edge of the plastic section of the undertray
    • Lift the metal section of the undertray into position

    • The front edge of the metal will fit over the top of the rear edge of the plastic section of the undertray

    • To secure, push the skidtray forwards onto the four tabs that will hold it in position

    • Reinstall the two Phillips head screws and tighten until snug using a Phillips screwdriver

    • Reinstall the six quarter-turn screws and tighten using a large Flathead screwdriver. These will "click" into position when tight

  33. Secure the bumper to the fender liner using the four OEM Phillips head screws removed in step 4. Tighten until snug using a Phillips screwdriver Position the upper headlight trim just above the headlight and gently push it inward to connect the two clips to the headlight
    • Secure the bumper to the fender liner using the four OEM Phillips head screws removed in step 4. Tighten until snug using a Phillips screwdriver

    • Position the upper headlight trim just above the headlight and gently push it inward to connect the two clips to the headlight

    • Often these clips will connect themselves when the bumper is reinstalled. If not, there will be an audible click as they are positioned

    • Repeat on the other side of the vehicle

  34. Replace the OEM hood weather stripping on top of the top edge of the bumper and secure with: One large push clip
    • Replace the OEM hood weather stripping on top of the top edge of the bumper and secure with:

    • One large push clip

    • One medium push clip

    • Three small push clips

    • Repeat on the other side of the vehicle

    • Reinstall the upper radiator panel and secure with 11 push clips removed in step 3

  35. Reinstall the rubber tab in the corner of the OEM air duct onto the upper radiator panel
    • Reinstall the rubber tab in the corner of the OEM air duct onto the upper radiator panel

    • Reinstall the weatherstripping onto the upper radiator panel. The five clips will click into place

  36. Check or boost leaks.
    • Check or boost leaks.

    • Check for boost leaks at all intercooler and piping connections

    • Once the car is up to temperature, complete a drive in which you can get the engine into high boost

    • If a whistling sound is heard, you may have a small boost leak, check and tighten the connections for the intercooler and piping

  37. This completes the installation of your 27WON Performance FK8 Intercooler
Finish Line

Dozuki System

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