User Manual Q&AAnswer
Mar 06, 2025 - 09:22 PM
To install the HS Motorsports 122004 Intercooler Pipe Upgrade Kit, please follow these steps:
1. Disconnect the batteries and remove the intake air temperature sensor connector and clip from the backside of the factory intercooler pipe. Remove the clip holding the intake air temperature sensor wiring to the fan shroud.
2. Remove the factory power steering reservoir bolt at the fan shroud and set it aside. Lift the power steering reservoir out of the retainer guide on the fan shroud and set it aside. Loosen the t-bolt clamp at the factory intercooler connection.
3. Remove the large locking C-Ring from the factory cold-side intercooler pipe at the throttle body assembly. Be careful not to damage the ring as it will be re-used later. With everything disconnected, carefully remove the entire cold-side intercooler pipe assembly from the vehicle.
4. Using a small flat-head screwdriver or other small tool, gently pry up on the factory intake air temperature sensor locking tab to release it while twisting the sensor counter-clockwise to remove it from the factory intercooler pipe. Install the sensor into the supplied HSM throttle adapter by pressing the sensor into the hole and twisting clockwise until fully locked.
5. With a pick or other small-ended tool, carefully remove the O-Ring from the inside of the factory intercooler pipe. Clean the O-Ring of any oil or debris and apply a small amount of Vaseline or Assembly Lube/Grease to the O-Ring. Install the O-Ring to the groove inside the HSM throttle adapter by starting on one side and working all the way around, ensuring it is fully seated in the groove.
6. Install the previously removed large locking C-Ring onto the HSM throttle adapter. Find the previously unplugged harness belonging to the intake air temperature sensor and route the wiring behind the power-steering reservoir. Plug the connector back into the intake air temperature sensor.
7. With the HSM logo on top and the intake air temperature sensor facing the front of the vehicle, carefully install the HSM throttle adapter to the factory throttle body assembly by applying pressure while slightly twisting the HSM throttle adapter back and forth until the C-Ring is locked into place. Be careful not to damage the sealing O-Ring, intake air temperature sensor, or harness during this step.
8. Using brake cleaner or another similar cleaning media, clean the factory intercooler boot sealing surface on the intercooler.
9. Fully loosen (without removing nuts) and slide the two supplied T-Bolt clamps onto the supplied 90-degree silicone coupler. Slide the supplied 90-degree silicone coupler onto the longer leg of the supplied intercooler pipe. Install the supplied straight coupler onto the shorter leg of the supplied intercooler pipe. Clamps for the straight coupler will be installed at a later time.
10. Install the new intercooler pipe assembly to the vehicle by sliding the 90-degree silicone coupler onto the intercooler and then working the straight coupler onto the HSM throttle adapter. Adjust the pipe and couplers to ensure that everything is lined up properly and that there is adequate room for clamps on all clamp locations.
11. While holding the lower 90-degree coupler and T-Bolt clamp tight against the intercooler, tighten the clamp. Make any necessary adjustments and then also tighten the other T-Bolt clamp on the 90-degree coupler.
12. Locate the supplied T-Bolt clamps and completely remove the nuts. Open the clamps and install them around clamp locations on the straight coupler. After ensuring proper fit and alignment, tighten these clamps.
13. Use the supplied HSM power-steering reservoir relocation bracket and ¼” hardware to loosely install the bracket to the reservoir. Using the factory reservoir bolt, install the other end of the bracket to the factory location. Adjust the reservoir so it is not binding or contacting other components and tighten all hardware.
14. Zip-tie the intake air temperature wiring to the nearby coolant line. Reconnect batteries and double-check all installed items for proper fitment. Test drive the vehicle to ensure all parts were installed correctly.
15. Please make sure to check the level of the coolant in the secondary cooling system. Failure to do so may cause overheating of the intercooler system and premature boot failure.
The installation is now complete.
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