Custom Intercooler Install on the Fd Rx-7: Enhancing Power and Reducing Intake Temps

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The FD RX-7 is renowned for its lightweight design and exceptional handling, but to unleash its full potential, enhancing the power and reducing intake temperatures is crucial. One of the most effective modifications is the installation of a custom intercooler. This article will guide you through the process of installing a custom intercooler on your FD RX-7, highlighting the benefits and steps involved.

Understanding Intercoolers

An intercooler is a heat exchanger used to cool the intake air charge of a turbocharged or supercharged engine. By reducing the temperature of the air entering the engine, it increases air density, leading to more efficient combustion and improved power output.

Benefits of a Custom Intercooler

Installing a custom intercooler on the FD RX-7 offers several advantages:

  • Increased Power: Cooler air allows for denser air intake, resulting in more power.
  • Improved Efficiency: Enhanced cooling leads to better combustion efficiency.
  • Reduced Knock: Lower intake temperatures help prevent engine knock.
  • Custom Fit: Tailored designs can optimize the fitment and airflow for your specific setup.

Choosing the Right Intercooler

Selecting the appropriate intercooler is critical for maximizing performance. Consider the following factors:

  • Core Size: Larger cores offer better cooling but may require modifications for fitment.
  • End Tank Design: Efficient end tanks improve airflow and reduce turbulence.
  • Material: Aluminum is lightweight and offers excellent thermal conductivity.
  • Brand Reputation: Choose reputable brands known for quality and performance.

Tools and Materials Needed

Before starting the installation, gather the following tools and materials:

  • Tools:
    • Wrench set
    • Screwdrivers
    • Cutting tools
    • Drill with bits
    • Measuring tape
    • Torque wrench
  • Materials:
    • Custom intercooler
    • Silicone hoses
    • Clamps
    • Mounting brackets
    • Heat-resistant tape

Step-by-Step Installation Guide

Follow these steps to install your custom intercooler:

  • 1. Prepare the Vehicle: Park the FD RX-7 on a level surface and disconnect the battery.
  • 2. Remove the Old Intercooler: Detach the existing intercooler and hoses. Take note of the connections for reinstallation.
  • 3. Measure for Fitment: Use a measuring tape to determine the space available for the new intercooler.
  • 4. Modify Mounting Points: If necessary, drill or cut mounting points to accommodate the new intercooler.
  • 5. Install the New Intercooler: Position the intercooler and secure it using the mounting brackets.
  • 6. Connect Hoses: Attach silicone hoses to the inlet and outlet of the intercooler, ensuring a snug fit.
  • 7. Secure Clamps: Tighten all clamps to prevent any boost leaks.
  • 8. Reconnect the Battery: Once everything is in place, reconnect the battery.
  • 9. Test for Leaks: Start the engine and check for any leaks in the system.

Tuning After Installation

After installing the intercooler, it’s essential to tune your engine to take full advantage of the upgrade. Consider the following:

  • ECU Remapping: Adjust the engine’s ECU settings to optimize performance with the new intercooler.
  • Dyno Testing: Conduct dyno tests to measure performance gains and ensure the engine runs smoothly.
  • Monitor Temperatures: Use gauges to monitor intake temperatures and make adjustments as needed.

Conclusion

Installing a custom intercooler on your FD RX-7 is a powerful way to enhance performance and reduce intake temperatures. By following the steps outlined in this article, you can enjoy increased power, improved efficiency, and a more reliable engine. Remember to tune your vehicle after installation for the best results and always prioritize safety during the process.