HOLDEN COLORADO (RG) INTERCOOLER KIT...HOLDEN COLORADO (RG) INTERCOOLER KIT ENGINEERING THE UNFAIR...
Transcript of HOLDEN COLORADO (RG) INTERCOOLER KIT...HOLDEN COLORADO (RG) INTERCOOLER KIT ENGINEERING THE UNFAIR...
INSTALLATION GUIDEHOLDEN COLORADO (RG)INTERCOOLER KIT
ENGINEERING THE UNFAIR ADVANTAGE
P/N PWI66175K – INTERCOOLER | P/N PWA64553 (2012-13) – PIPE KIT
ContentsCONDITIONALMANUFACTURERSWARRANTY...............................................................................................2
Warrantyvoids.........................................................................................................................................2Warrantydoesnotcover.........................................................................................................................2
LIMITOFLIABILITYSTATEMENT.....................................................................................................................2
SAFETYPRECAUTIONS...................................................................................................................................3
IMPORTANTINFORMATIONFORFITTING......................................................................................................4
RADIATORS:.................................................................................................................................................4INTERCOOLERS:............................................................................................................................................4OILCOOLERS:..............................................................................................................................................4LIQUIDTOAIRBARRELINTERCOOLERKITS:.........................................................................................................4
APPLICATION.................................................................................................................................................5
PACKINGLIST................................................................................................................................................5
EQUIPMENTANDSUPPLIESREQUIREDFORFITMENT....................................................................................6
DISASSEMBLY................................................................................................................................................7
ASSEMBLY...................................................................................................................................................11
AssemblySection1–Intercooler...........................................................................................................11AssemblySection2–PipeKit.................................................................................................................13
INSTALLATION INSTRUCTIONS - NOVEMBER 2016 2
CONDITIONALMANUFACTURERSWARRANTYPWRCustomAluminiumRadiators,IntercoolersandOilCoolersalongwithcoresonlyfortheseunitsarewarrantedtotheoriginalpurchasertobefreeoffaultformaterialsandworkmanshipforaperiodof1yearfromthedateofpurchaseandonlywhenusedundernormaloperatingconditions.Claimsforinternaldamagetoengineorotherrelatedcomponentsofuser’svehiclearenotcoveredbythiswarranty.ThePWRproductuserisresponsibleforthemonitoringofenginetemperatureoperationsandforhavingtheappropriatedetectiondevicesinplacetowarntheuserofoverheatingandotherenginerelatedmalfunctions.Attimeofinstallationanapprovedcoolantmustbeaddedtothecoolingsystem.(Seeimportantinformation–Radiatorpoint3)Responsibilityforanydamage,injuryorlossattributedtoanyfaultinmaterialorworkmanshipintheabovelistedproductsshallbelimitedbyreplacingtheunitonreturnofthedefectiveproduct.
Warrantyvoids
IftheproductisrepairedorweldedbyanotherpartyotherthanPWRPerformanceProducts.*Ifanydefectisattributabletoanaccident,abuseornegligence.*Wheretheproductisusedforanapplicationforotherthenitwasintended.*Ifanypartsoraccessoriesarefittedwhichadverselyaffecttheproduct
Warrantydoesnotcover
Chargerelatingtoremovalandreplacementtovehicle.*Internalorexternalcorrosion.*Anyconsequentialdamage.*FreightcostincurredtosendtheitembacktoPWR
LIMITOFLIABILITYSTATEMENTTheinformationcontainedinthispublicationwasaccurateandineffectatthetimethepublicationwasapprovedforprintingandissubjecttochangewithoutnoticeorliability.PWRPerformanceProductsreservestherighttorevisetheinformationpresentedhereinortodiscontinuetheproductionofpartsdescribedatanytime.
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SAFETYPRECAUTIONS
STOPCAREFULLYREADTHEIMPORTANTSAFETYPRECAUTIONSandWARNINGSBEFOREPROCEEDINGWITHTHEINSTALLATION!Appropriatedisassembly,assemblymethodsandproceduresareessentialtoensurethepersonalsafetyoftheindividualperformingthekitinstallation.Improperinstallationduetothefailuretocorrectlyfollowtheseinstructionscouldcausepersonalinjuryordeath.Readeachstepoftheinstallationmanualcarefullybeforestartingtheinstallation.
• Alwayswearsafetyglassesforeyeprotection.
• PlacetheignitionswitchintheOFFposition.
• Alwaysapplytheparkingbrakewhenworkingonthevehicle.
• Blockthefrontandreartyresurfacestopreventunexpectedvehiclemovement.
• Operatetheengineonlyinwell-ventilatedareastoavoidexposuretocarbonmonoxide.
• Donotsmokeoruseflammableitemsnearoraroundthefuelsystem.
• Usechemicalsandcleanersonlyinwellventilatedareas.
• Batteriescanproduceexplosivehydrogengaswhichcancausepersonalinjury.Donotallowflames,sparksorflammablesourcestocomenearthebattery.
• Keephandsandanyotherobjectsawayfromtheradiatorfanblades.
• Keepyourselfandyourclothingawayfrommovingpartswhentheengineisrunning.
• Donotwearlooseclothingorjewellerythatcanbecaughtinrotatingormovingparts.
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IMPORTANTINFORMATIONFORFITTINGPleasereadthefollowingbeforefittingourPWRPerformanceProduct.
WARNING:Failuretofollowthisprocedurewillvoidyourwarranty.
• Donotusethisproductinanyothermotorvehicleforwhichitisnotdesigned.• Donotuseanyothermountinglocation/methodotherthandescribedinthisinstruction.• Itisadvisabletoseekassistanceofanotherpersonwheninstallingthisproduct.• Donotrepairormodifythisproductand/oritsmountingbracketinanyway-repairormodificationmay
affectproperoperationofthevehicleorcausedestructionofproperty.• Ensurealltorquesettingsarefollowed.• Besuretocleanandremoveanyloosedebrisbeforeremovingpipeworkasdebrisenteringtheengine
couldbedetrimentaltotheengineandorcomponents
Radiators:• Beforeremovingtheoldradiatorchecktheexistingcoolantforstraycurrent.Thisisdonebyconnectinga
voltmeterbetweenthecoolantandthebatteryground.Themetershouldhavearangeofatleast12volts(assumingthevehiclehavea12voltchargingsystem)andasensitivityofatleastone-tenthofavolt.Byconnectingonetestleadtobatterygroundandplacingtheotherleadintothecoolant(DONOTTOUCHTHEMETALCOREORFILLERNECK)anyvoltageindicatescurrentpassingthroughthecoolant-ELECTROLYSIS.
• Ifnocurrentfoundflushcoolingsystemwithdistilledwatertoremovetheexistingcoolant/inhibitors.Whentheentiresystemhasbeenflushedincludingtheoverflowbottles,youcanfitthenewradiator.DONOTMIXCOOLANTS
• SelectacoolantthatisrecommendedbythemanufacturedorbyPWR.ProductmustmeetthecurrentAS2108ormanufacturesenginecoolant/inhibitorstandardandrefillsystem.Bringengineuptotemperatureandletcool.Re-Checkthecoolantlevelandtopupifnecessary.USEONLYDISTILLEDWATER.
• IMPORTANT-againrecheckstep1foranystraycurrent.• PLEASEbecarefulwhenfittingandmakesureallmountingpointsaretight(tomanufacturers
specifications)andthereissufficientclearancesonorubbingoccurs.• PLEASEensurethatallhoseclampsaredoneup.• Correctcapmustbeusedforeachindividualsystem.
Intercoolers:• PLEASEbecarefulwhenfittingandmakesureallmountingpointsaretight(tomanufacturers
specifications)andthereissufficientclearancesonorubbingoccurs.• PLEASEensurethatallhoseclampsaredoneup.
OilCoolers:• PLEASEbecarefulwhenfittingandmakesureallmountingpointsaretight(tomanufacturers
specifications)andthereissufficientclearancesonorubbingoccurs.• PLEASEensurethatallhoseclampsaredoneup.• Donotrunover80psirating.
LiquidtoAirBarrelIntercoolerkits:• SelectacoolantthatisrecommendedbythemanufacturedorbyPWR.Productmustmeetthecurrent
AS2108enginecoolant/inhibitorstandardandrefillsystem.Cyclethefluidsthroughthesystemtoremoveairlocks.Re-Checkthecoolantlevelandtopupifnecessary.USEONLYDISTILLEDWATER
• PLEASEbecarefulwhenfittingandmakesureallmountingpointsaretight(tomanufacturersspecifications)andthatthereissufficientclearancesonorubbingoccurs.
• PLEASEensurethatallhoseclampsaredoneup.• Pumpmustbefittedinaccordancetofittinginstructionssuppliedandbyaqualifiedautoelectrician.
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APPLICATIONBeforecommencingtheproceduresoutlinedpleasereadtheguideandverifyallpartsarepresentandnotdamaged.Ifanythingismissingordamaged,pleasenotifyPWRPerformanceProductson0755471600.
PACKINGLISTDescription PartNumber QuantityAirInduction55mmColoradoIntercooler PWI64552 1
HotIntercoolerIntakePipe 01.64553 1
ColdIntercoolerOutletPipe 02.64553 1
SiliconeHose51mmx135Degree 15A19105 1
SiliconHumpHose51mmx80mmlong 15A19101 2
SiliconHose62mmx113Degree 15A19104 1
MurryHoseClamps50–73mm TSS36S30EP00C 6
MurryHoseClamps64-86mm TSS40S30EP00C 2
HornSpacers 02A19221 2
M6flatwashers MSFWM6Z 2
BoltM6x25SocketHeadCapScrew SHCSM625ZP 2
BoltM6x10SocketHeadCapScrew SHCSM610ZP 1
Clips-Ducting GM94215211
Decals/LabelsWarrantyCard 1
10
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EQUIPMENTANDSUPPLIESREQUIREDFORFITMENT• FenderCover(2)
• 1/4"and3/8"DriveRatchetswithExtensions
• 3/8"DriveTorqueWrench(7-35ft-lbrange)
• MetricSocketSets(shortanddeeprecommended)
• MetricWrenchSets
• MetricAllenKeySet
• T-25,T-27ANDT-30TorxBitScrewdriversorSockets
• ShortPhillips-headScrewdriver
• Smallflatscrewdriver
• TrimPadTool(forpushpinremoval)
• AssemblyLubricant(WhiteLithiumGreaseorPetroleumJelly)
• SharpKnifeorRazorBlade
• Hacksaworsnips(tocutplastic)
• MediumStrengthThreadLocker–Loctite®242(blue)orequivalent
• Writingequipment(penormarker)
• Ziplock/resealablebags(tostoreandlabelremovednuts/boltsclipsetc.)
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DISASSEMBLYThefollowingsectionwillguideyouthroughthedisassemblyoftheOEMpartsonyourvehicle.Specialcareshouldbetakentolabelpartsandavoiddamagingitemsasremovedsincemanyitemswillbereused.
1. Openbonnet.2. Coverguardswithfendercoverstoprotect
vehiclefinish.
3. DisconnectBattery.
4. Removeenginecover(Ensureitisfreefromloosedebrisandslideacleanragundertocoverovertheoilfillertoavoidcontaminationofenginewhenremoving)
5. RemovebumperstartingwiththetopedgeofthegrilleusingT15torxandM10socket
6. Nextremovethescrewsunderthewheelwellconnectedthefrontbar.
7. Disconnectfoglightsiffittedatthisstage.
8. UsingaM10andM14socketsundothescrewsunderthefrontlipofthebumper.
Removedebrisandcoverholeasshown
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9. Afterallscrewsareundonecarefullyprythebumperusingtrimremovaltool.Itisrecommendedtohaveasecondpersontohelpholdthebartopreventdamagingthebarduringremoval.
10. Undothescrewsholdingthelockpanelcoverandremovethepanel.
11. Removethecoversovertheairbagsensorstogainaccesstotheductingandreinforcementbar.
12. Undothelasttwoboltsinthemiddleofthereinforcementbarandremove.
13. Disconnectandremovethehorns.
14. Removetheductingusingatrimremovaltool.(Breakclipsforspeedyremovalasnewclipsaresuppliedinthekit)
15. Removethelockpanelcoversupportrods.
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16. Removethebonnetlatchbraceandunclipthesensorfromthebacksideofthebrace
17. Removebonnetlatchandresttotheside(NOTE-itisrecommendedtotemporarily securewithziptieifrequiredtopreventit slippinganddamagingpanels.)
18. Unboltthelowerreinforcmentbumperbarin4places.(2oneachside)
19. DisconnecttheMAFplug.
20. Undotheintakepipeandremovetheairboxcover.
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21. Undothehoseclampsfromthetopoftheintercooler.
22. RemovetheclampsthatretaintheOEMRubberintercoolerpipesfromthesteelhardpipe.Thenundoandremovethesteelhardpipefromtheradiatorcoresupportpanel.
23. Undoandremovethehotpipefromtheturbo.
24. Undoandremovethecoldpipefromthethrottlebody.
25. UnboltandremovetheOEMintercooler.
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ASSEMBLYThefollowingsectionwillguideyouthroughtheassemblyofthePWRPerformanceProductsupgradedintercoolerandpipekitinstallationinyourvehicle.
AssemblySection1–Intercooler1. RemovetherubbergrommetsfromtheOEM
intercoolerandplacethemintothePWRintercooler.
2. Installthe2inchsiliconehumphose(Partnumber15A19101)ontotheintercoolerinletandrotatehoseclamparoundasindicatedbeforesecuring.Mirrorthisfortheintercooleroutlet.
3. Reinstalltheintercooleronthecarusingtheoriginalmountingpoints.Takingcaretocarefullyslidetheoutletsthroughtheholesintheradiatorcoresupportpanelbeforethebottompinsarepushedinasitisasnugfit.
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4. Reinstallthebonnetlatchandbrace.(NOTE–usetheM6x10mmscrewsuppliedinthekitinthesecondholeofthebraceasindicatedintheimagebelowtoavoidcoredamage.Asthebraceisclosetothecore.Thereshouldbeagapofatleast5mm.)
5. Reinstallairsensorharness.
6. Undotheboltinthecenterofthehornandrotatethebracketaroundsothattheplugsdonothittheintercoolerwhenreinstalled.
7. Screwthehornonwiththealuminiumspacerbehindthebrackettoclearthelipontheradiatorcoresupportpanelandconnectplugs
8. TrimtheductingforboththeleftandrighthandsidesalongtheredlinesasshowntoclearthenewPWRintercooler.
9. Reinstallairductingbyclippingintoplaceusingthesuppliedclips.
Minimum5mmgap
SuppliedM6screw
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10. Reinstallthebumperreinforcementpanel,lockpanelsupportsandthelockpanel.
AssemblySection2–PipeKit
EnsuretorquesettingarecorrectforMurryclampstoavoidunderorovertensionofclampswhichmayleadtofailure.RatedUltimateTorque:75in.lbs.min.(8.5Nm)RecommendedInstallationTorque:50in.lbs.(5.6Nm)
11. Installthe135degreesiliconelbowontotheturbo.Slideonhoseclampsbutdonottightenuntilthehardpipeisinstalled.
12. InstallthehotsidePWRhardpipe01.64553intothe135degreeelbowandslipintothe2inchhumphoseontheintercooleratthesametime.
13. Confirmthatthesiliconisharduptotheshoulderonthehoseoutlets,checkclearancesandtightenupallhoseclampsfirmly.
14. ReinstallthefilterboxcoverandcoldairintakebackontothefilterboxbesuretoreconnecttheMAFplug.
MAF Plug
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15. Installthecoldpipeandthebyslidingintheintercoolerendfirst.Thenslipthethrottlebodyendofthetubeintopositiontoandrotatesiliconandaluminumpipingtomakesurethatnothingisrubbing.
16. Ensurethesiliconeispushedallthewayontotheribbedoutletandtightenupallhoseclampsfirmly
17. Itisrecommendedtouseasocketthathasauniversaljointandappropriateextensionstogettothehardtoreachhoseclampsbehindtheradiatorcoresupportpanel.
18. NextstepistomovebacktothefrontofthecarandreplacethefrontbumperandGrillcombo.
19. Ensurethatallthelightsarereconnectedbehindthebumperbeforetighteninguplowerfixingscrews.
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20. Connectbatteryandconfirmthatallhoses,pipes,wiresandpanelsaresecure.
21. Ensure thatnotoolsorobstructionshavebeenleft underthebonnetandyourPWRIntercooler andpipekitisnowinstalled.
22. Checkalllightsandsensorsthatmayhavebeendisconnectedduringtheinstallarenowfullyfunctional.
23. EnjoyandthankyoufromtheteamatPWR.