Looking at the crash beam, there are two circular cutouts that are of equal distance from the center of the beam. In the driver’s side hole, on the back wall, there is a dimple. You’re going to want to drill a hole with the ¼” drill bit right into this dimple. Let the drill do the work and keep the bit lubricated with a quality cutting fluid like Tap Magic. Apply steady force to the drill and only drill at about ¼ to ½ speed. If you go full throttle on the drill you’ll ruin the bit and have a bad time. The bumper is tough to drill through so be patient, go slowly, and use plenty of lube.
Once you break through, repeat the process with the larger drill bit. Remember, slow and steady wins the race here. Make sure to reapply cutting fluid as you go.
Loosely install the COBB core onto the front of the vehicle. The larger, 90 degree angle brackets rest up against the backside of the crash beam. The thinner, bent brackets on the bottom rest on top of the lower radiator support. Using the supplied 6mm bolt and flange nut and flat washer, loosely locate the lower brackets into the pre-drilled holes in the radiator support. The core should rest easily in place with the mounting holes on the top of the core aligning with the circular cutouts in the bumper beam.
With the core in place, align the hole that was just drilled with the corresponding mounting hole. Loosely install the 8mm hardware through this hole to locate the core in a more defined position. It should look slightly off center if you drilled into the dimple at the back of the cutout. (Shown Below)
Now for the tricky part. Using the permanent marker, you’ll want to mark the inside back wall of the crash beam where you’ll be drilling in relation to where the mounting hole on the intercooler is behind it. This is tricky because other than eyeballing it and gathering a sense of where the hole should be, there isn’t a great way to ensure its correct. If all things are lined up correctly, you should be drilling in the exact center of the opening.
- Using a center punch in order to mark this point can help to allow the drill a bit more initial bite and accuracy.
With the ¼” drill bit, drill your pilot hole through the bumper beam. Once through, you’ll be able to tell if you are close enough to move forward with drilling with the larger drill bit. If not, you now have a better estimate where the hole should be and can re-drill a new pilot hole.
With both holes drilled, you can now fully install the COBB core onto the bumper beam using the supplied 8mm bolt, flat washer, lock washer, and nut.
Remove the MAP sensor off of the factory intercooler core and install it into the endtank of the COBB core using the supplied M5x16 socket head cap screw and 5mm flat washer.
Remove the reducing pipe and silicone mounted on the throttle body to make way from the new COBB charge piping.
Install the 2.5” straight coupler onto the throttle body. Install and tighten a 2.5” T-Bolt clamp to hold it in place.
Install the 2.5” silicone elbows onto either end of the intercooler. The shorter side should connect to the core. Loosely install a 2.5” T-Bolt clamp to hold it in place. You’ll need to be able to rotate the clamp when installing the pipes so don’t tighten them down quite yet.
- Using a 10mm socket, remove the two fasteners that hold the passenger side of the radiator support in place. You may also need to drill out a silver rivet to allow it to hang freely. (Some cars have this rivet and others haven’t) Once loose, pull the rubber grommet out of the lower radiator support to allow the support to drop. This will allow you room to install the cold-side charge pipe connecting the passenger side of the core to the throttle body.
Install the cold pipe between the throttle body and the intercooler along with two (2) t-bolt clamps.
Install the silicone reducing elbow onto the turbo with the 2” T-Bolt clamp. Leave it loose for now.
Install the turbo pipe between the turbo and the intercooler along with two (2) 2.5” T-bolt clamps. Leave them loose for now.
Using the supplied grommets, aluminum bushing spacers, and 6mmx25mm bolts, install the turbo charge pipe to the block.
The order in which these are installed is: Grommet — Aluminum Spacer (flat area facing away from the car) — Bolt.
Example pictures of arrangement:
With all the silicone and charge piping in place, go back and tighten down the t-bolt clamps until snug. Some adjustment of the silicone may be necessary to achieve the best fitment.
Reinstall the 10mm fasteners that hold the radiator support in place. Make sure to reinsert the rubber grommet at the bottom.
Tighten the 6mm hardware that secures the lower brackets of the intercooler core to the radiator support.
Use the supplied zip tie to secure the grill shutter connector in place.
Reinstall the bumper in the reverse order you removed it; don’t forget the fog light connector. Make sure to reinstall the rubber shrouds. The lower shroud will now be held in place with only the upper torx bolts.