Well as most of you know, I fitted the first of Courtenays new Front Mounted Intercooler to my Zafira the day before PV2004. Now I have covered 800 miles with it, including going to Devon and back, heres my report.
1) The Kit - Contained the following
1. The Intercooler
2. The IC to Boost Pipe Alluminuim Transfer Pipe
3. Various Silicon Hose and clips, brackets and bolts.
This was alot easier than I thought, once stripped down (Bumper, cross member and old IC removed) it looked like this :-
On the top of the FMIC there are two captive bolts for you to bolt the bracket to, of the two L shaped brackets, simply drill a hole in each and bolt them to the FMIC. Once this is done, re-fit the cross member and offer up the FMIC.
You can then see where the two brackets which are bolted to the FMIC will line up with the cross member. Two solutions are possible here, either drill two more holes through the cross member and simple bolt in place, or you can weld the brackets to the cross member, the choice is yours.
Once this is done, I offered up my bumper to check for clearance, fortunatly on the Zafira the bumper did not have to be touched, I also think the GSi bumber and SRiT bumper may have enough clearence. The Coupe 'may' need a little internal trimming, but nothing too harsh. You of course will not see this from the outside.
The other alluminium transfer pipe has a bracket witha small hole in it, this simply bolts to the left hand side (Looking at the front of the car) where the O/E IC was fitted. The air flow sensor and boost pipe simply fit where they did on the original IC.
The section of blue silicon hose supplied simply connects the two together using Jubilee clips.
Using the 90o Silicon elbow, fit this to the inlet side of the FMIC so it goes round the radiator assembly, using the existing turbo hose that comes out the bottom of the turbo, line the two up and cut the original hose, and using the ally connecting tube, connet these together.
The finished result (Less the Inlet hose connected) :-
Well the initial start up was promising, the exhaust note was imediatley deeper and nice. Out on the road the difference was noticed straight away, the car pulls harder without as much effort and the original Mantzel Flat Spot is much much reduced than before.
The general running of the car is smoother, as said before the pick up is better. At higher revs, the turbo appears to hold the boost a little better as well, maybe this is because of the reduced inlet temp.
So with the new software going in in August, things look good. After driving to Devon at a steady 70mph, the car returned an average of 38mpg which was better than before.
but the best was the average mpg, it used to be around the 24mpg mark, but around the hills of Devon we covered 110 miles in urban type driving and the mpg did not drop below 28mpg.
So I personally thing this has been a very well chosen mod, alot easier to fit than I thought and well worth the money.