NME5005 ULTRIK Water-to-Air Intercooler Installation Instructions

KIT CONTENTS

INSTALLATION SUMMARY

It is best to install the individual assemblies, connect the hoses, connect the wiring, then fill and purge the system.  The reservoir and pump installation is the most 'challenging', and the rest is fairly straightforward.

The following is the recommended sequence for installation:

1. Reservoir and pump
2. Radiator
3. Intercooler
4. Hoses
5. Wiring

INSTALLATION INSTRUCTIONS

Reservoir and Pump

The installation of the reservoir and pump is the most time consuming portion of the installation.  These components are placed in the compartment at the back of the engine bay on the passenger side, next to the ABS hydraulic control unit.  Holes need to be drilled for the mounting bolts, inlet and outlet hoses.

1. Place the reservoir and pump assembly in the compartment at the back of the engine bay on the passenger side as shown.

2. Align the brackets and drill 1/4" holes for the mounting bolts as shown.

3. Place one or two nuts to temporarily hold the components in place while determining hose routing locations in the compartment.

4. Mark the location for the inlet hose as shown.

5. Mark the location for the outlet and overflow hoses as shown below.

6. Remove the reservoir and pump.

7. Drill 1" holes for the inlet and outlet hose as marked.

8. Take the 'shorter' straight hose and attach to the pump outlet.  Some lubricant may be necessary as the fit can be tight.  Secure the hose with a hose clamp.

9. Attach the overflow hose (small diameter hose) to the overflow at the base of the cap.  Allow the hose to drain into the bottom of the compartment.

10. Carefully insert the pump and reservoir into position by feeding the outlet hose through the opening.
 
11. Mount the pump and reservoir using supplied nuts and bolts.

Radiator

1. Install the radiator as shown.  Slide the right side tab into the slot and secure with the supplied 6mm x 12mm bolt and washer on the left side.

Intercooler

Removal of the stock intercooler is straight forward.  Note the following:

o Be careful not to damage the sealing bellows when removing and installing the intercooler.
o Be careful not to allow any debris to enter the intake plenums.
o Installing the new intercooler onto the bellow takes some 'finesse' - don't rush or use excessive force.
o Make sure the sealing bellows are fully seated before re-installing the clamps.
o Don't over tighten!

1. Remove the intercooler cover as shown.

2. Remove the stock intercooler as shown.  Remove the clamping bolts closest to the intercooler and remove the top half of the clamps.  Loosen the clamping bolts on the plenum side.  When removing the intercooler, it may be necessary to push the intercooler all the way to one side while lifting the other end.  After freeing one side, pull out to remove the unit.

3. Below is a photo with the intercooler removed.

4. Install the ULTRIK intercooler by inserting the larger end into the larger sealing bellows and carefully fitting the smaller bellows over the other end.  Confirm the bellows fits completely over the intercooler - especially the bottom side.  Make sure nothing hits the underside of the intercooler.

5. Re-install the clamps and clamping bolts.  Tighten to 9Nm (7 ft-lb).

Hoses

Note the following when installing the hoses:
o Choose the shortest distance where possible when routing the hoses.
o Hoses to and from the intercooler must have enough slack to allow for engine movement. 
o Make sure the hoses behind the grille do not obstruct the hood closing.
o Secure the hoses using plastic tie wraps to prevent unwanted hose movement.

1. Take the remaining 'longer' straight hose and attach it to the left side of the radiator (passenger side).  Route the hose through the foam as shown.

2. Route this hose straight back to the pump and attach.

3. Take the hose with a 90 degree bend and attach it to the right side (drivers side) of the radiator.  Route the hose through the foam as shown.

4. Route this hose to the front side outlet of the intercooler, attach the 90° fitting and secure to the intercooler with supplied clamp.

5. The only remaining hose connection should be the previously attached pump outlet hose.  Attach this to the back side inlet to the intercooler but do not tighten.  (You will need to pour water into this hose to prime the pump later.)

Electrical Connection

Wires can be spliced to sources using the supplied crimp connectors which will function adequately.  However it is always recommended that connections be soldered and wrapped for best results.

Power for the pump is supplied through a relay to isolate the circuit.  The relay is triggered by a 'switched' +12V source which activates when the key is in the 'on' position.  Check the presence of voltages before you splice.  DISCONNECT THE BATTERY BEFORE MAKING THE CONNECTIONS.

See the attached supplement (last page) for proper relay connections.  Mount the relay in a convenient location, preferably in an 'upright' position.  (The drivers side engine mount is a good location for the relay, drill a small pilot hole and use a self-tapping screw to secure the relay).  Electrical connection diagram is below.

Double check to make sure the appropriate wire is connected to the correct relay terminal.

ELECTRICAL CONNECTIONS - SIMPLIFIED SCHEMATIC

1. Position the relay and check to make sure all wires will reach the required destination.  Route the wiring from the pump along the back side of the engine compartment over to the relay. 

2. See below for the attachment point for the switched +12V.

3. Attach the red wire from pin 86 on the relay to the 'Switched +12V source shown below.

4. Attach the black ground wire from the pump to chassis ground.  Attach the black wire from pin 85 of the relay to chassis ground.  There is a Ground Point on the front side of the strut tower next to the connector shown above.

5. Make sure the battery is disconnected. Connect the fused yellow wire from pin 30 on the relay to the 'HOT' 12V source shown below.  This is a cable directly from the battery.

6. Check all connections.  Make sure wires to not touch any moving engine parts, or any hot exhaust components. 

SYSTEM TEST

1. After checking all hose clamps are properly tightened, fill the system with a 50% mix of anti-freeze with water.  Fill a container such as a plastic bottle to help ease the filling of the reservoir - use a funnel if available.

2. Fill the reservoir with the coolant mixture.  If you spill the coolant mixture on any part of the exterior body panels, rinse off immediately.

3. Remove the inlet hose on the back side of the intercooler and fill the hose with the coolant mixture.  This will help prime the pump.  Re-attach and secure with a clamp. 

4. To help speed up the 'filling' process, you can disconnect the outlet hose from the intercooler (front side) and fill it with the coolant mixture - this will help fill the radiator.

5. The next step may require an assistant.  Be prepared to continue filling the reservoir as your assistant turns the key to the 'on' position and activates the pump.

6. Continue filling the reservoir with the coolant mixture until the return hose circulates the coolant mixture back into the reservoir.

7. (If an assistant is not available, run the pump for a few seconds, stop and fill the reservoir, and repeat until the level remains stable.)

8. Install the cap and let the system run for a couple minutes with the car running - it may take some time for all the air pockets to work free.  Shut off and check for leaks and top off if necessary.

9. If no leaks are found, take a drive around the block allowing the engine to reach operating temperature.  After returning, check the fluid level in the reservoir and look for leaks again.

10. If no leaks are present - you are all set!

11. Make it a point to check the water level weekly.

12. If the water level should change, find the leak and correct.

SUPPLEMENT

Connections
The terminals of a relay are defined as follows:
* 30 is the common or input voltage (or ground) to be switched.
* 87a is the normally closed connection (can be used as a switched voltage output when the relay is at rest). (This terminal offers no voltage when the relay is energized.)
* 87 is the normally open connection (switched voltage output when the relay is energized).
* 85 is connected to the ground of the triggering voltage.
* 86 is connected to the positive 12V of the triggering voltage.

Note: in many cases, the connection of pins 85 and 86 can be interchangeable, but NOT if there is a diode wired across the coil.