Congratulations on your purchase of the COBB Tuning Intercooler! The following instructions will assist you through the installation process. Please read them BEFORE beginning the install to familiarize yourself with the steps and tools needed. If you feel you cannot properly perform this installation, we HIGHLY recommend you take the vehicle to a qualified and experienced automotive technician.
Park your car in a flat, level area and allow it to cool down properly.
Remove the two 12mm bolts from the throttle body to the intercooler using your ratchet.
On the driver's side (USDM) remove the 12mm bolt through the intercooler itself, the two holding the bracket to the intake manifold can be left installed.
Remove all three 12mm bolts on the passenger's side (USDM) and take the bracket out of the engine bay for now.
Gently pry out on the retaining clip spring until it sits in it's unlocked position (It should stay there without need of holding it with a tool)
Pull the hose connection out of the charge pipe and tilt the intercooler to remove it from the engine bay.
Stock Hood Shroud Disassembly
If you have a hard time reaching or don’t want to worry about dropping too many things in the engine bay, removing the entire shroud can make things easier. Start with removing the trim clips on the sides by pulling the center outward and then removing the whole clip.
Don’t forget the ones on the back corners!
Now the last one in the center under the hood
With that the shroud should fold downand you can easily slip the hooks out of the back.
Remove the trim clips going around the outside of the rubber gasket on the factory ducting. This can be done by pulling the inside smaller circle portion outward and then using your trim tool to pull the outer portion out of the hole.
Once they’re all off it should just flop off the ducting and you’ll have it loose!
Loosen the outermost clamp from the rubber coupler holding the charge pipe together. Then remove the outer barbed portion from the coupler. Then do the same with the rear mostclamp until you have the three parts of the charge pipe disassembled. (Doing this while the pipe is still installed to the intercooler will give you a bit mroe weight and leverage to hold things in place) It can sometimes help if you get a pick under the rubber to break things loose, but be careful not to poke a hole in anything.
Remove the three bolts holding the factory charge pipe to the stock intercooler.
Transfer the charge pipe onto the new intercooler.
Reassemble the charge pipe using the provided coupler and clamps in place of the factory rubber ones.
Remove the metal insert from the rubber bushings on the stock intercooler, then remove the rubber portion.
It can then be installed into the new core. (the large flat side of the insert should be on the top side away from the side with the charge pipe on it.
Very Carefully remove the o-ring from inside the stock intercooler using a small pick. Any tears may cause issues later on.
You can then slide it into the new intercooler
Assemble the four pieces of the shoud using the supplied hex key, and the 6 Allen bolts.
Use the snubby looking trim on the back side (opposite the cobb logo) on the portion without the bolt holes.
Using the pointy duck head looking one, go around the other three sides of the opening in the shroud. You can get as fancy or as lazy in the corners as you want, making angled cuts where they meet up etc.
COBB Thrust Tunnel Installation
Using the original push pins/trim clips, attach the thrust tunnel to the underhood shrouding. Once you get one in, evrything should be fairly easy to line up.
At that point you can reinstall the shroud to the car if you uninstalled, or you’re all finished with this step!
Intercooler Core Installation
First get the COBB intercooler under the lip at the back of the engine bay
Get the charge pipe lined up in place and push it in until it clicks, make sure the snap ring falls into place.
Rotate the intercooler around the charge pipe to get the throttle body into place on the intercooler.
Loosely install the passenger's side bracket with the stock bolts.
Repeat with the driver's side.
Bolt down the throttle body with the two factory bolts, then tighten down the two outside brackets. It’s a good idea to gently wiggle the intercooler upward and towards the throttle body until you feel the bolts going in smoothly to avoid cross threading.