colt cztint

8/8/2019 Colt Cztint

1/19

FMCZTINTMitsubishiColtCZTfront

mountingintercoolerinstallation

Toolsneeded:

Drillwith8mmHSSdrillbit,hacksaw,dremel/stanleyknife

3/8driveratchetwithextensionand10mm,13mmsockets

TorxT25andT30bits

7mmhoseclipdriveror7mmsocket

6mm

allen

key

or

socket


2/19

KITLIST

1xintercooler

1xhornbracket

2x50mmdiametersiliconjoiner

2x50mmdiameter90degreesiliconelbow

1x50mmdiameter90degreealuminiumelbow

1xcustomaluminiumpipewithturbooutletflangeononeend

1xcustomaluminiumpipewith45degree bendononeend

8x4560mmjubileeclips

6xM8pennywashers

2xM8x40allenheadbolts

2xM8x12allenheadbolts

2xM8nylocnuts


3/19

1. Jackthefrontofthecarupintheairandsupportonaxlestands.DONOTworkunderthecarwithjustajacktakingtheweight.Openthebonnet.Workinginthe

wheelarches,removethe8mmselftappingscrewatthetopofthearchandthe

poppertypefixinghalfwaydownthearch,byleveringundereachsideofthe

popperuntil

it

can

be

withdrawn.

Do

this

on

both

wheel

arches.


4/19

2. Removethefrontnumberplate(ourswasstuckonuseheatfromahairdryertosoftentheglueandbendtheplateoffslowly)andpulloutthefixinginthemiddleof

thebumper.

3. Workingunderthefrontofthecar,removetheengineundertraybyremovingthe15(yes

15)

popper

style

fixings,

5down

each

side.


5/19

.andfiveunderthefront.Theundertrayshouldnowpullfreetowardsthebackof

thecar.

4. Stillunderthecar,removetheedgesofthebumperformthewheelarchliners,twooneachsideofthecar.


6/19

5. Underthebonnet,undothefourT30screwsholdingthetopofthebumpertotheslampanel.TAKECAREtoremovethecorrectfourscrewsasindicated.LEAVETHE

TWOMIDDLESCREWSLOOSELYSCREWEDINitwillstopthebumperfromfalling

offinthenextstep.

6. Workingonthewheelarch,placeyourhandunderthearchlinerbehindthebumperandpullsharplyoutwardsthebumperisheldfirmlyinplacebythreeplasticclips.


7/19

Plasticclipsforreference:

7. Repeatonbothside,thenremovethetwoT30screwsyoustillhadlooselyscrewedin.Supporttheweightofthebumper,andpullitforwardslightlytoreachdownand

undothewiringtothefoglights(simplysqueezetheconnectortoremoveit),then

removethe

bumper

and

place

somewhere

safe.


8/19

8. RemovethepassengersideheadlightbyundoingthethreeT25retainingscrews,thenreleasethewiringfromtheundersidebysqueezingontheplastictabsbefore

removingitfromthecar.


9/19

9. Workingbackunderthefrontofthecar,locatetheturbooutletpipe,andusinga10mmsocket(ideallyasixsidedsocket)undobothofthestarshapedbolts.Retain

thegasketforfutureuse.

10.Undothehoseclampholdingtheintercoolerinletpipefromthebottomofthestockintercoolerandremovethewholepipefromthecarwiththeturbooutletattached.


10/19

11.Undothethree13mmretainingboltsholdingtheintercoolertothechassis.Oneofthemisuparoundthebackoftheintercoolerandwillrequirealongextensionpiece

onyourratchet.Undotheintercoolertophose(atbothends),andremovethe

intercoolerfromthecar.Removethetoprubberintercoolerhosefromthecaralso.


11/19

12.Younowneedtomounttheintercoolerontothebumperbar,butyouneedtoremovethebumperbarfirst.Unclipthebonnetreleasecable,removethesingle

10mmboltinthecentreandthetwo13mmnutsoneachendofthebarandremove

itfromthecar.


12/19

13.Offeruptheintercoolertothebumperbar.Themountingholesonthebracketsare295mmapart.Takethe10mmboltonthetopofthebarasthemiddle,eachofyour

holesneedstobe147.5mmtotheleftandrightofthecentreofthathole.Marktwo

linesonthebartorepresentthis,thenofferthecoreup.Pushthecorehardagainst

theback

of

the

bar,

with

the

brackets

over

the

lines

you

already

drew,

and

mark

the

middleoftheholeforeachbracket.Thiswillbewhereyoudrillyourholes,andifall

hasgonetoplan,thecoreshouldbeinthemiddleofthebar.

14.LooselymountthecoretothebumperusingtheM8x12bolts.Putapennywasherundereachboltthenpushthroughtheintercoolerbracket,thenonepennywasher

betweenthebracketandthetopofthebumperbar.SecurewiththeM8nutinthe

cavityaccessedfromthefrontofthebar.

147.5mm


13/19

15.Remountthebumperbartothecar,withtheintercoolerstilllooselyattached.Theintercoolerneedstorestontheledgeatthebottomoftheradiatorcowling,oncein

place,tightentheintercoolermountingbolts.Iftheintercoolerneedsspacing

upwards,wehaveprovidedtwosparepennywasherstoplacebetweenthetopof

thebumper

bar

and

the

underside

of

the

intercooler

brackets.

16.Mountthetwo50mmsiliconcouplerstotheendsoftheintercooler,andthenlookattheintercoolerfromthesideandmarkuptheareasoftheplastictrimaroundthe

cowlingthatneedstoberemoved,thenremovethetrimbypullingitawayandcut

outtheplasticwithadremelorsimilar(Stanleybladeworkstoo).


14/19

17.Withthetrimremoved,youalsoneedtocutoffthelocatinglugfromtheradiatorcowlingsoitscompletelyflush,andundotheT25screwholdingthehornbracket.

18.Undothe13mmnutfromthebackofthehornunit,andremovethebracket.ReplacewiththeForgehornbracketsupplied,andremountthehornwiththe

bracketangled

towards

the

back

of

the

car.

Locatin lu


15/19

19.Usingahacksaw,cutthebottomleft(fromthefrontofthecar)rearedgeoftheradiatorcowlapprox60mmlongand10mmdeepata45degreeangleuptothe

reinforcingintheplastic.


16/19

20.NowtoinstallthepipeworkfindthehardpipewiththeCNCdturboflangeonit,andthegasketyouremovedearlierfromthestockturbooutlet.UsingtwoM8x20

allenheadboltsandasuitableallenkey,bolttheturbooutletpipeintopositionwith

theoutletpointingtotheleft(fromthefrontofthecar).


17/19

21.Jointhe90degreealuminiumelbowintooneofthe90degreesiliconelbowstoforma180degreebend.Placetwohoseclipslooselyonthe90degreesiliconbend,and

twohoseclipslooselyboth50mmcouplersalreadyontheintercoolerfromstep16.

Observetheorientationoftheclipsasshownbelow,whichwillmakeiteasierto

tightenthem.

Join

the

turbo

outlet

hose

to

the

intercooler.

You

may

need

to

adjust

thehoses,andmightfinditeasiertolubricatethesiliconhoseswithasiliconspray

(dashboardcleaner/backtoblackworkwell).

Whenthepipeworkisinplaceandyouhaveatleast20mmofaluminiumpipework

ineachendofthesiliconhose,tightenalltheclips.Youwillfinditeasiesttotighten

thesilicontoturbooutlethosefromtheback.


18/19

22.Ontheothersideofthecar,placetheremaining90degreesiliconhoseontheendofthestockpipeworkundertheheadlight,togetherwithtwoloosehoseclips.

Inserttheremaininghardpipeintothecouplerontheintercooler,andthenpushit

upinto

the

90

degree

bend

just

added.

When

it

fits

well,

tighten

all

the

hose

clips.


19/19

23.Yourinstallshouldnowbecomplete,andlookinglikethis:

Followsteps7to1toreplacethestockbumper,andenjoyyournewintercooler.

ENGINEEREDFOR

PERFORMANCE

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