So tomorrow could be the big day. I finally have everything I need for my 2" IC from Wbody.
W-body Intercooler kit; Tubing, Bosch pump, bolts, Lower Intake Manifold, Supercharger Gaskets, Valve Breather, Core, Heat exchanger, O-Rings
ZZP Billet Fuel rails
Turn down Adapter
Injector O-Rings
Valve Breather
Intake gaskets
Add-a-fuse
Alternator Relocation Bracket
EGR block off plate
Aluminum Valve covers
3.4" Pulley

Does anyone know of a decent write up for installing an intercooler? The one I've found shows you have to cut the hood latch but its an install on an older generation car. Also the heat exchanger looks alot bigger than mine (26"x7"). Here's a couple questions I haven't been able to find answers for yet.
With a shorter exchanger do you need to cut the hood latch for the install?
Is there any good way to get the fuel rails off without getting everything covered in fuel?


Thanks again guys!

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

Personally havent found a write up but takes lots of pics and do a write up

Sent from my SGH-I897 using Tapatalk

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Damn it I know I was forgetting to do something while I was doing.that.

sent from my driod x, via my fingers through tapatalk

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2001 white gt coupe with enough crap to make it run mid 13's with 3 bad pistons
2002 40th GTP sedan mostly stock

Lol. I'm doing it by candle light tonight. Except for the fuel rail parts, those I'm doing blind. Got the rails off with just alittle fuel coming out but nothing much getting into the injector holes that I could see which is a nice bonus.

Calling it a night and draining the rad first thing tomorrow.

I guess I just answered my own question. On ZZP's inter cooler description it says for the 3800 inter coolers there is no cutting required. Score.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

It's pretty straightforward. You will more than likely need the EGR code deleted out of the PCM since you are blocking it off. Hopefully you don't have emissions inspections where you live because it will fail a visual emissions inspection. I would suggest an oil change when the isntall is complete because when you pull the LIM some coolant will probably get in the engine. I'm surprised you don't have to cut the lower portion of the hood latch, but maybe the 04+ don't have that. You will know pretty quick when you install the radiator.

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1997 TGP

I have my HPTuner ready to roll and I need an oil change anyway. No emission's testing where I live as long as I stay away from car shows, they got raided by the Insurance company and the Police and I think about 100 tickets and 5 cars were impounded. Not score.

Going to clean up my supercharger tomorrow since I'm blocking off the EGR I figure a cleaning will go a long way with it. I also have a coupler I can replace mine with if need be.

Is there any reason I shouldn't use copper RTV for my LIM gasket corners and the coolant temp sensor?

Thanks again guys!

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

You should use Teflon tape for the temp sensor nothing else. I've only used red RTV for the corners of the LIM during install, so I can't answer your other question

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1997 TGP

Ok, it looked like they're was RTV on the sensor so that's what I threw on it. On the LIM bolts it looked like they originally had teflon tape or the thread locker tape. Do you guys know which one it would be exactly?

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

Thread locker

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1997 TGP

Ok, so everything is on and... The booster cap hits the liner on the hood. My rails look like they are flawed.

/sigh
I guess I'll cut a hole in the hood liner. Depending on how it looks underneath maybe I'll just leave the liner off. If the car burns she burns. lol
And another week or two depending on what happens with the fuel rails.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

No teaser pics even? I was wondering if you would.have hood issues or not. Cradle spacers can help that too, I got luck and have miles of hood clearence.

sent from my driod x, via my fingers through tapatalk

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2001 white gt coupe with enough crap to make it run mid 13's with 3 bad pistons
2002 40th GTP sedan mostly stock

I thought you had to run modded rails or purchase aftermarket fuel rails to run a 2"+ intercooler? Do you have any leaks at the injectors?

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1997 TGP

These are ZZP Billet rails. I will let you know about leaks when this finally happens though

The fuel rails were sent with the wrong connector. They sent a straight connector that is ment to come off the regulator on the previous gen's billet rails. I need the elbow.


So while we wait for this rail business to transpire. I cleaned the blades on my supercharger. What odds are you guys giving me that it's going to explode?

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

ask steve the modded fails are nto a garenty of working with a 2" core lol

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92 LeBaron Convert: Turbo 3L 97 Grand Prix GT 4dr "Frankenstein": L67 4t65 swap
97 Grand Marquis: Summer DD 99 Grand Prix GTP: Top Swap Beater

no pics?

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No pics, my phone is 4 years old and my computer doesn't read the chip for it any more for some reason. I put my money into my car and this phone was an old business phone that the business still pays for.

I just ordered cradle spacers, pump controller and some needle bearings for the supercharger just as a precaution.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

Com on $30 bucks will.get a super.cheap point and shoot digi cam. Lol. Gotta tease.
Mater the rails fit fine. The connecting hose was just to.short ( me.thinks it was for a short stack.)

sent from my driod x, via my fingers through tapatalk

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2001 white gt coupe with enough crap to make it run mid 13's with 3 bad pistons
2002 40th GTP sedan mostly stock

^^^ get a facebook email to upload pics and than you txt the pics to that email

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i can text pics to my normal Email on my 4 year old phone

your just being lazy lol

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92 LeBaron Convert: Turbo 3L 97 Grand Prix GT 4dr "Frankenstein": L67 4t65 swap
97 Grand Marquis: Summer DD 99 Grand Prix GTP: Top Swap Beater

I just think its an error, it seems like a lot of stress on the line to have it connect vertically to anything.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

i was just giving crap. sometimes chit dont work they way we would want.

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2001 white gt coupe with enough crap to make it run mid 13's with 3 bad pistons
2002 40th GTP sedan mostly stock

Damn! so cradle spacer's are a must for clearance?
I though maybe a guy could make it by without. sucks to go IC on 04+ you have to spend an extra 200+ bucks to get clearance

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Comp G: 3.2-E85-65's-headers-rockers-104's-DHP tune & "other stuff that doesn't matter"

You don't NEED to have cradle spacers. I have closed the hood. If you cut a 2" hole in your hood liner to make room for the booster cap you should be fine. You probably do need to use a turn down though. I haven't put the TB on without it but it would be the highest point I'm sure. Cradle spacers would probably be easiest.. I've had my cradle undone before too to take apart the tranny and its not that hard, you could make your own too if you really wanted to save some cash.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

IIRC cradle spacer's change your front ends alignment with your axles etc. so i wanna try and avoid using them.
Also, would you say the alt. relocation bracket was a must?

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Comp G: 3.2-E85-65's-headers-rockers-104's-DHP tune & "other stuff that doesn't matter"

I have one but I haven't gotten the alternator on yet. I want to make sure I get the fuel rails are going to fit properly before I put that into my way.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."