jeremy irons
Member
When I decided to do an eBay Front mount intercooler, I first read this thread front to back to decide how I want to go about it.
I decided:
- I did not want to cut a big chunk out of the crashbar
- I did not want to block the foglight holes in the bumper
- I did not want to remove the windshield washer tank or block the CAI hole
I made a list of parts, and ordered it all up on ebay. I totally forgot that I would need parts to make an intake since I did not already have a CAI, so I had to buy those parts locally.
Parts:
- FMIC kit : https://www.ebay.com (commissions earned) $159
- 2x 2.5" -> 2.75" couplers for the MAF $22
- 1x 2.25" > 2.5" coupler for turbo inlet $11
- 1x 2" > 2.5" coupler for turbo outlet $11
- 2.5" pipe with BOV flange to suit BOV of your choice (I went with an HKS) $24
- BOV $100 (used)
- 2x 2.75" T bolt clamps for MAF $14
- 8" length of 1/8" vacuum hose or BOV $1
- 2x M8x1.5mmx25mm Flange bolts $laying around
- 2x M10 washers(very large) $laying around
- Assorted scrap metal to make brackets $laying around
- some ~1cm thick bits of hard rubber or plastic $laying around
- Cone filter if you don't already have an intake.$60
total: $402
tools
- Drill
- holesaw kit
- hacksaw
- dremel or cutoff wheel
- tinsnips
- ratchets and combo wrenches (ratcheting boxwrenches are nice too)
- tiny flathead for dealing with plastic body clips
Procedure:
Take the front bumper off. Here are some how-to's on that.
http://www.aggressiveautoculture.com/protege/bumper_brackets/AAC_Protege_Bumper_Install_Guide.pdf
http://www.motobild.com/mazda/2003-mazda-protege5-front-bumper-removal-installation.html
http://en.wikibooks.org/wiki/Mazda_Guide/Protege_5/Headlight_Blackout
Remove drivers side fan and the old FMIC. actually maybe you don't have to but I didn't want to leave them in there. Make a bracket to hold the bottom of the rad. You can re-mount the top rad mount to hold the top. Remove all the intercooler piping and filter box.
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