Ford Focus ST front mounted intercooler fitting instructions.
If these instructions are unclear in any way then please see http://www.forgemotorsport.co.uk/content.asp?inc=media and download the master copy. Tools required: Vehicle ramp or Jack and axle stands, T25 Torx driver, T30 Torx driver, 8mm spanner, 10mm socket, ratchet and extension bar, Pozzidrive screwdriver, Flat blade screwdriver, Trim removal type tool, Protective clothing, footwear and eyewear are also recommended. 1/ Raise the vehicle on a ramp or place on axle stands. Open bonnet. Remove the six plastic screws from the upper slam panel/radiator cowling; remove this cowling and then the 2 plastic screws underne ath this. Remove the single top T30 screw from each headlight, slide the headlights forward and release the electrical connections, completely remove the 2 headlights. Remove the 2x T30 screws from the front edge of each front wheelarch, remove the single 10mm bolt from the upper front edge of each front wheelarch. Remove the 3x 10mm screws from the bumper to wing/fender line on each side of the front bumper. Unclip the 7 upper plastic tags on the front bumper. Remove the 2 plastic screws from the underside of the front bumper. Disconnect the front fog light electrical connections. Disconnect the bonnet release lock from the front grille. If the car has headlight washers then remove the covers by simply extending the jets and unclipping the covers. The front bumper cover can now be lifted clear of the vehicle.
2/ Remove the 2 plastic air guides. These are fixed with a single T30 screw on each side. These will not be refitted later due to the new larger intercooler fitment.
3/ Loosen the 2 lower hose clips from the original intercooler pipe connections. Remove the 2x 8mm bolts from the intercooler lower fixings. Now lift the intercooler slightly in order to remove it from its upper mountings and then ease forwards whilst removing the 2 hose joints. Completely lift original intercooler away from the vehicle.
4/ Remove the complete horn assembly by removing the centre 10mm Bolt, Hang the assembly over the front of the crash bar for the time being. Remove the original spe ed clips from the lower edge fixings of the original intercooler; fit these to the lower brackets on the new intercooler. 5/ Now fit the new Intercooler in to place; ease on the right side hose connection as the intercooler is being lifted in to place. Refix the lower mountings by re using the original bolts. Fit the left side hose connection. Tighten all fixings and hose clips.
6/ Fit the horn bracket to the boss in the top edge of the new intercooler using the m8 bolt supplied. The 2 horns may require slight adjustment on the bracket to give clearance to the radiator. Tighten all fixing nuts and bolts once in place.
7/ Now refit the complete front bumper in reverse of removal. Note, the 2 lower edge plastic screws will not be refitted as these located the air guides which also do not require refitting. You are now ready to enjoy the new performance of your vehicle.
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