FM intercooler upgrade for NA
FM intercooler upgrade for NA
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Description
When we redesigned our turbo kits in 2006, we came up with a lighter, more efficient intercooler and piping design.
The collection of complex steel pipes and long routing has been replaced with molded silicone hoses that take a direct route from the turbo to the intercooler and have a smooth interior for better flow. They're also lighter and have fewer failure points.
The intercooler is a more effective "long tube" design with a more direct airflow. The mounting is adjustable and solid while blocking less airflow to the radiator than the previous "wings". It's powder-coated for durability and good looks, but with a special thermal property that allows it to shed heat as well as bare aluminum.
Despite the major redesign, we were able to keep the new components compatible with our older kits. This upgrade includes a new wastegate actuator bracket, all the piping from the turbo to the throttle body, the new intercooler, a new lower radiator hose and all the other small bits and pieces needed (such as constant-torque and T-bolt hose clamps). Fits the GT2560R (GT28R or Big Ball Bearing) turbo. NB FM I and FM II cars with the Link piggyback ECU will require a new compressor inlet hose, air filter, and air filter mount pipe (if you're not using the MAF).
This could work with non-FM kits, but there are some dimensions you'll need - the compressor outlet is a 2" inside diameter, and the intercooler uses 2.5" hoses. The BOV port is a 1-3/8" inlet.
All this for the price of one of our old intercoolers without any piping!
If you have an adjustable wastegate on your existing turbo, you will need to buy a non-adjustable wastegate. No wastegate is currently included in the upgrade.
Instructions
Instructions are not currently available.
Shipping
What does it fit?
Fits: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997
Emissions
Not legal in California.
Warranty
1 year
SKU
One year later review. For the price of this kit it should come with a bottom intercooler mount. The silicon hoses do not provide the rigidity of a hard plumbed or hybrid (silicon elbows, aluminum pipes). As a result, the bottom of the intercooler wobbles like a loose tooth. Consequently, a) inlet/outlets keep developing leaks due to movement; b) outlet hose from intercooler rubs against sway bar; c) Silicon hose rubs against engine under tray cutouts - cutting into expensive hose.
I am in the process of designing and fabricating a lower mounting bracket that uses stock OEM radiator bottom mounts studs to correct the movement issue.
FYI: when you place stand-offs between radiator & intercooler and then ratchet strap the two together; a) the intercooler outlet hose moves 1" away from the stabilizer bar; b) the intake hose moves away from top radiator hose (doesn't rub as bad).
Note from FM: This isn't a problem that we've experienced on our kits - while the intercooler can move a small amount, it's not enough to rub and develop leaks when everything is installed properly. If the undertray is cutting through the hose, the hole should be cut larger and/or buffered with split hose.
Installation was very easy. Almost enjoyable. No surprises and the kit is pretty well engineered. Only complaint is the cheap intercooler clamps. When used as directed the poor design of the clamps causes the socket to slip off the hex nut. I ended up re-using my existing clamps as they worked better and didn't feel as cheap. Based on the cost of the upgrade kit this was pretty disappointing. Given the cost of the upgrade kit there really should be no excuse.
NOTE FROM FM: We're currently working with this customer to get them the correct sized hose clamps.
I just got this kit a few weeks ago and did a video review to highlight my impressions and offer a few tips when installing. I also offer a few suggestions to FM on how they could make it better. all this is outlined in the video. One suggestion I will make on here is that FM do a separate install video for this kit specifically. As quite a few things are a bit different to the normal install since the turbo is already mounted, and the ways you need to go a different direction from the normal turbo install. Overall I love this kit and it is a major improvement for all aspects of the turbo kit. Here is the link to the video.
https://youtu.be/pDvCbvlS7YI