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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
Old 03-13-2010, 07:41 PM
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Crotchety Old Bastard
 
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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.
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RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 03-13-2010, 08:11 PM
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Thanks Brian,

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

Greg
Old 03-13-2010, 08:45 PM
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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
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Mods: TurboKraft Custom IC, 934 Headers, GSX 61, Zork, Port Work, SC Cams, Air Mod Fuel Dist Relocated, Water Meth Injection, BL WUR, MSD 6530, Greddy EBC, Synapse Bov, Short 2nd & 3rd with 8:37 R&P, Wevo Shifter, Coupling, and Mounts, MTX-L SSI-4, Big Brakes, Rebel Coilovers, Bilstein Sports.
Old 03-14-2010, 09:44 AM
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This was my 930 engine with a 964 intercooler fitted, not sure if the pics help





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87 930, 993 turbo engine, RS Tuning 520PS/515lbf-ft, Arrow Rods, ARP hardware, Solid lifters, G50-50, RS Flywheel, 890nm Sachs clutch, RSR coil overs all round, 993 C4 calipers front, 930 fronts on the rear, Ruf Speedlines.....
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Old 03-14-2010, 10:55 AM
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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
Old 03-15-2010, 01:01 PM
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My 964 Intercooler pics








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
Old 03-15-2010, 03:51 PM
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OFF THE BOOST PIPE NOW...
 
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I once had a 964 intercooler and bought the parts to install it. Ended up selling it for a Kokeln.

Anyway, here's a parts list I had:

Old 03-15-2010, 05:20 PM
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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
Old 03-15-2010, 08:21 PM
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Thanks Lou, Any photos would be great
Old 03-16-2010, 02:16 AM
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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.
Old 03-16-2010, 10:45 AM
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Quote:
Originally Posted by aerodyn930 View Post
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.

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





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Old 03-16-2010, 11:05 AM
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Quote:
Originally Posted by elvision930 View Post
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.
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
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87 930, 993 turbo engine, RS Tuning 520PS/515lbf-ft, Arrow Rods, ARP hardware, Solid lifters, G50-50, RS Flywheel, 890nm Sachs clutch, RSR coil overs all round, 993 C4 calipers front, 930 fronts on the rear, Ruf Speedlines.....
Old 540 BMW, XB12S Modified, for being a total hooligan
Old 03-16-2010, 11:29 AM
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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, Lou

Old 03-16-2010, 07:38 PM
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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
Old 03-19-2010, 08:33 PM
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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.
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Old 03-19-2010, 08:37 PM
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Would anyone know this bits part number?




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





Do I use this pipe?

Old 03-19-2010, 08:47 PM
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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?





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




Thanks for all your help

Greg
Old 03-19-2010, 08:55 PM
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^^^ 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.
Old 03-20-2010, 04:09 AM
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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
Old 03-21-2010, 01:04 AM
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