964 Intercooler Setup Help
 

Hi,

I recently purchased a 964 Intercooler for my 1978 Euro 930 to go with my RarlyL8 headers & exhaust, 1 bar spring, adj WUR, and K27S turbo.

Looking at the shipping tracking it will finally arrive from the USA in the next day or two.

I think the 964 intercooler I purchased also comes with the 964 pipe to the turbo, a 964 plastic BOV and the plastic pipe to the air box?

Unfortunately no mounting brackets or any other piping other than above comes with the Intercooler.

I was wondering if anyone had fitted one of these 964 Intercoolers before and how hard it was to fit to a CIS 930. What worked, what didn't, how you mounted it, and plumbed it up.

What other parts are needed from the 964 car's set up and what parts did you modify from your existing 930 setup? Will I get more HP from running the 964 plumbing setup or is the 930 plumbing set up better, or do I use a combination of both the two systems?

Does anyone have diagrams of the two systems?

What changes, modifications do you make to the way hoses and piping is run?

Any ideas and photos of how you fitted it up would be really appreciated.

Thanks,
Greg

Take inventory of what you get with the intercooler when it arrives. There are several bits and parts. If something is missing we can help you out. Not a difficult swap.

Thanks Brian,

I'll post some photos when I finally get it.

Greg

Greg,

If you do a search here. Someone, kindly, posted a Kokeln install with pictures
and it's basically identical. It will show you how to replace the recirculation assembly and that would be were you're going to have most of the questions. Hope that helps and good luck. I do have that install info saved if you would want to send me an E-mail address.

Cole

This was my 930 engine with a 964 intercooler fitted, not sure if the pics help

http://i139.photobucket.com/albums/q...bouttogoin.jpg

http://i139.photobucket.com/albums/q.../Enginepic.jpg

http://i139.photobucket.com/albums/q...epicforren.jpg

Thanks Cole and Jonathon

Cole, I sent you my email any info you have would be a great starting point.

Thanks for the pics, Jonathon, Can you remember what parts you used from the 964 and what you had to make up?

I'm about to pick it up this morning (snuck the morning off work). I will try to upload some photos of the parts that came with it.... I have just hope it survived the long journey o.k.

Greg

My 964 Intercooler pics
 

http://forums.pelicanparts.com/uploa...1268693195.jpg
http://forums.pelicanparts.com/uploa...1268693212.jpg
http://forums.pelicanparts.com/uploa...1268693227.jpg
http://forums.pelicanparts.com/uploa...1268693244.jpg
http://forums.pelicanparts.com/uploa...1268693262.jpg
http://forums.pelicanparts.com/uploa...1268693306.jpg

Here are the photos of what I have

What are all those outlets for? Looks rather complicated.

Any ideas and suggests on how to tackle and what else I need to buy would be much appreciated.

Thanks
Greg

I once had a 964 intercooler and bought the parts to install it. Ended up selling it for a Kokeln. :confused:

Anyway, here's a parts list I had:

http://forums.pelicanparts.com/uploa...1268698816.jpg

Hello, Having done a couple of these installs, I would like to offer some info:

1- turbocharger to I/C inlet hose (very expensive , if yours is not serviceable a
replacement can be fabricated)
2-Coil bracket,( it has a different location for the I/C rear mount.
3-main I/C support mounts (they are mounted on intake manifold),
4-auxiliary air valve to I/C hose (different layout)
5-90 degree duct out of air flow meter with provision for recirculating(BOV) valve
6-Stock or aftermarket recirc. valve
7-Block off plate for Intake temp sensor
8-after removing your factory recirc. valve housing(if applicable) a connecting tube is needed between the 90 degree duct out of air flow meter to the metal duct going to turbocharger inlet.

as you know the A/C condenser has to be relocated out of the spoiler, also fabricate a restrictor baffle to promote airflow thru the I/C core.

as I am in the process of testing different I/C's will provide photos in a day or so.

If you need any of these parts fabricated, P. M. me

Regards , Lou
AERO DYNAMICS

Thanks Lou, Any photos would be great

Sorry off topic. The picture with the intercooler on the engine. Your fan and fan housing look great. Did you polish it up or chrome it. Mine looks really oxidized and I want it to look like yours. Any ideas.

No. 1 above can be replaced with a 2" section of aliminum tube with an approximate 30 degree bend at the end, a 2 inch silicon "hump" hose and a 2"-3" silicon reducer.

No. 3 I used threaded heim joints and stainless tube in conjunction with small "L" brackets to attach the inetrcooler to manifold.

No. 8 I originally used a 3" aluminum tube with a 3" - 2.75: silicon reducer to connect to the factory air intake tube but have recently replaced with a custom 3" aluminum air intake tube with NO kinks.

Pics below


http://forums.pelicanparts.com/uploa...1268762623.jpg


http://forums.pelicanparts.com/uploa...1268762686.jpg

I think it was lightly sprayed with some silver paint, didn't look like that for long! I would think powder coat would be best, but i have no idea if i'm honest

Some photos of the parts: The two rear brackets are mounted on the manifold, the one with the long hexagonal body substitutes one of the nuts on the manifold for cyl #4, the other mounts on a threaded hole next to the rubber mount for the a/f meter. The photo of the coil bracket shows the different layout, finally the shot of the recirc. valve mounted on the 90 degree duct out of the A/F meter,

The plumbing, Drivers side: 1-waste gate
2-Deccel. valve(if not on your car, plug nipple)
3-Recirc. valve
Pass. side 1-aux air valve

regards, Louhttp://forums.pelicanparts.com/uploa...1268793213.jpg
http://forums.pelicanparts.com/uploa...1268793283.jpg
http://forums.pelicanparts.com/uploa...1268793388.jpg

Sorry for the slow reply but go called out of town for work on short notice...as usual

Thanks Lou

And Thanks everyone for your pics and help.

I'm just starting to get my head around it. But sorry in advance for all the questions. especially for the dumb ones...lol

I need the below list of bits? Anything else you can think of?

1. BOV Boost hose (93011038200)
2. 964 BOV (got one)
3. 90 deg rubber elbow (between turbo to intercooler pipe) 93011025900
4. 1 X Aircooler support (93011022302)
5. 2x Air cooler Support Bracket Rubbers

Can anyone tell me what part number that coil bracket Lou posted is?

After I remove the recirculation assembly what do I need to connect the 964 intercooler to the inlet body

In the photo of Jonathons 964 what are the senders fixed to the intercooler and do I need to buy theses bits?

On my 964 intercooler what hoses get connected to outlets A B C D E ?

Thanks
Greg

I have a new in box 965 intercooler shroud (the one that attaches to the top of the intercooler). Let me know if you are looking for one.

Would anyone know this bits part number?


http://forums.pelicanparts.com/uploa...1269056463.jpg

What gets connected to these outlets A B C D E?
Do I need to buy any sensors?


http://forums.pelicanparts.com/uploa...1269056683.jpg


Do I use this pipe?

http://forums.pelicanparts.com/uploa...1269056743.jpg

David also sent me some good photos of a prepared engine bay

After I remove the Recirculation assembly what do I need to connect to the inlet?


http://forums.pelicanparts.com/uploa...1269057115.jpg


How do I and what do I need to connect to the inlet in the center of the photo?

http://forums.pelicanparts.com/uploa...1269057226.jpg


Thanks for all your help

Greg

^^^ The intercooler will sit on the throttle body above. The various mounts will hold it down.

IIRC, you can use the existing o-ring but order a few extra as they can tear.

Thanks A930Rocket, that gives me one end all sorted out. I'll get a few spare o rings.

I think I'm starting to get my head around some of it now.



Thanks,
Greg