HOLDEN COLORADO (RG) INTERCOOLER KIT...HOLDEN COLORADO (RG) INTERCOOLER KIT ENGINEERING THE UNFAIR ADVANTAGE P/N PWI66175K – INTERCOOLER | P/N PWA64553 (2012-13) – PIPE KIT Contents

INSTALLATION GUIDEHOLDEN COLORADO (RG)INTERCOOLER KIT

ENGINEERING THE UNFAIR ADVANTAGE

P/N PWI66175K – INTERCOOLER | P/N PWA64553 (2012-13) – PIPE KIT

ContentsCONDITIONALMANUFACTURERSWARRANTY...............................................................................................2

Warrantyvoids.........................................................................................................................................2Warrantydoesnotcover.........................................................................................................................2

LIMITOFLIABILITYSTATEMENT.....................................................................................................................2

SAFETYPRECAUTIONS...................................................................................................................................3

IMPORTANTINFORMATIONFORFITTING......................................................................................................4

RADIATORS:.................................................................................................................................................4INTERCOOLERS:............................................................................................................................................4OILCOOLERS:..............................................................................................................................................4LIQUIDTOAIRBARRELINTERCOOLERKITS:.........................................................................................................4

APPLICATION.................................................................................................................................................5

PACKINGLIST................................................................................................................................................5

EQUIPMENTANDSUPPLIESREQUIREDFORFITMENT....................................................................................6

DISASSEMBLY................................................................................................................................................7

ASSEMBLY...................................................................................................................................................11

AssemblySection1–Intercooler...........................................................................................................11AssemblySection2–PipeKit.................................................................................................................13

INSTALLATION INSTRUCTIONS - NOVEMBER 2016 2

CONDITIONALMANUFACTURERSWARRANTYPWRCustomAluminiumRadiators,IntercoolersandOilCoolersalongwithcoresonlyfortheseunitsarewarrantedtotheoriginalpurchasertobefreeoffaultformaterialsandworkmanshipforaperiodof1yearfromthedateofpurchaseandonlywhenusedundernormaloperatingconditions.Claimsforinternaldamagetoengineorotherrelatedcomponentsofuser’svehiclearenotcoveredbythiswarranty.ThePWRproductuserisresponsibleforthemonitoringofenginetemperatureoperationsandforhavingtheappropriatedetectiondevicesinplacetowarntheuserofoverheatingandotherenginerelatedmalfunctions.Attimeofinstallationanapprovedcoolantmustbeaddedtothecoolingsystem.(Seeimportantinformation–Radiatorpoint3)Responsibilityforanydamage,injuryorlossattributedtoanyfaultinmaterialorworkmanshipintheabovelistedproductsshallbelimitedbyreplacingtheunitonreturnofthedefectiveproduct.

Warrantyvoids

IftheproductisrepairedorweldedbyanotherpartyotherthanPWRPerformanceProducts.*Ifanydefectisattributabletoanaccident,abuseornegligence.*Wheretheproductisusedforanapplicationforotherthenitwasintended.*Ifanypartsoraccessoriesarefittedwhichadverselyaffecttheproduct

Warrantydoesnotcover

Chargerelatingtoremovalandreplacementtovehicle.*Internalorexternalcorrosion.*Anyconsequentialdamage.*FreightcostincurredtosendtheitembacktoPWR

LIMITOFLIABILITYSTATEMENTTheinformationcontainedinthispublicationwasaccurateandineffectatthetimethepublicationwasapprovedforprintingandissubjecttochangewithoutnoticeorliability.PWRPerformanceProductsreservestherighttorevisetheinformationpresentedhereinortodiscontinuetheproductionofpartsdescribedatanytime.


SAFETYPRECAUTIONS

STOPCAREFULLYREADTHEIMPORTANTSAFETYPRECAUTIONSandWARNINGSBEFOREPROCEEDINGWITHTHEINSTALLATION!Appropriatedisassembly,assemblymethodsandproceduresareessentialtoensurethepersonalsafetyoftheindividualperformingthekitinstallation.Improperinstallationduetothefailuretocorrectlyfollowtheseinstructionscouldcausepersonalinjuryordeath.Readeachstepoftheinstallationmanualcarefullybeforestartingtheinstallation.

• Alwayswearsafetyglassesforeyeprotection.

• PlacetheignitionswitchintheOFFposition.

• Alwaysapplytheparkingbrakewhenworkingonthevehicle.

• Blockthefrontandreartyresurfacestopreventunexpectedvehiclemovement.

• Operatetheengineonlyinwell-ventilatedareastoavoidexposuretocarbonmonoxide.

• Donotsmokeoruseflammableitemsnearoraroundthefuelsystem.

• Usechemicalsandcleanersonlyinwellventilatedareas.

• Batteriescanproduceexplosivehydrogengaswhichcancausepersonalinjury.Donotallowflames,sparksorflammablesourcestocomenearthebattery.

• Keephandsandanyotherobjectsawayfromtheradiatorfanblades.

• Keepyourselfandyourclothingawayfrommovingpartswhentheengineisrunning.

• Donotwearlooseclothingorjewellerythatcanbecaughtinrotatingormovingparts.


IMPORTANTINFORMATIONFORFITTINGPleasereadthefollowingbeforefittingourPWRPerformanceProduct.

WARNING:Failuretofollowthisprocedurewillvoidyourwarranty.

• Donotusethisproductinanyothermotorvehicleforwhichitisnotdesigned.• Donotuseanyothermountinglocation/methodotherthandescribedinthisinstruction.• Itisadvisabletoseekassistanceofanotherpersonwheninstallingthisproduct.• Donotrepairormodifythisproductand/oritsmountingbracketinanyway-repairormodificationmay

affectproperoperationofthevehicleorcausedestructionofproperty.• Ensurealltorquesettingsarefollowed.• Besuretocleanandremoveanyloosedebrisbeforeremovingpipeworkasdebrisenteringtheengine

couldbedetrimentaltotheengineandorcomponents

Radiators:• Beforeremovingtheoldradiatorchecktheexistingcoolantforstraycurrent.Thisisdonebyconnectinga

voltmeterbetweenthecoolantandthebatteryground.Themetershouldhavearangeofatleast12volts(assumingthevehiclehavea12voltchargingsystem)andasensitivityofatleastone-tenthofavolt.Byconnectingonetestleadtobatterygroundandplacingtheotherleadintothecoolant(DONOTTOUCHTHEMETALCOREORFILLERNECK)anyvoltageindicatescurrentpassingthroughthecoolant-ELECTROLYSIS.

• Ifnocurrentfoundflushcoolingsystemwithdistilledwatertoremovetheexistingcoolant/inhibitors.Whentheentiresystemhasbeenflushedincludingtheoverflowbottles,youcanfitthenewradiator.DONOTMIXCOOLANTS

• SelectacoolantthatisrecommendedbythemanufacturedorbyPWR.ProductmustmeetthecurrentAS2108ormanufacturesenginecoolant/inhibitorstandardandrefillsystem.Bringengineuptotemperatureandletcool.Re-Checkthecoolantlevelandtopupifnecessary.USEONLYDISTILLEDWATER.

• IMPORTANT-againrecheckstep1foranystraycurrent.• PLEASEbecarefulwhenfittingandmakesureallmountingpointsaretight(tomanufacturers

specifications)andthereissufficientclearancesonorubbingoccurs.• PLEASEensurethatallhoseclampsaredoneup.• Correctcapmustbeusedforeachindividualsystem.

Intercoolers:• PLEASEbecarefulwhenfittingandmakesureallmountingpointsaretight(tomanufacturers

specifications)andthereissufficientclearancesonorubbingoccurs.• PLEASEensurethatallhoseclampsaredoneup.

OilCoolers:• PLEASEbecarefulwhenfittingandmakesureallmountingpointsaretight(tomanufacturers

specifications)andthereissufficientclearancesonorubbingoccurs.• PLEASEensurethatallhoseclampsaredoneup.• Donotrunover80psirating.

LiquidtoAirBarrelIntercoolerkits:• SelectacoolantthatisrecommendedbythemanufacturedorbyPWR.Productmustmeetthecurrent

AS2108enginecoolant/inhibitorstandardandrefillsystem.Cyclethefluidsthroughthesystemtoremoveairlocks.Re-Checkthecoolantlevelandtopupifnecessary.USEONLYDISTILLEDWATER

• PLEASEbecarefulwhenfittingandmakesureallmountingpointsaretight(tomanufacturersspecifications)andthatthereissufficientclearancesonorubbingoccurs.

• PLEASEensurethatallhoseclampsaredoneup.• Pumpmustbefittedinaccordancetofittinginstructionssuppliedandbyaqualifiedautoelectrician.


APPLICATIONBeforecommencingtheproceduresoutlinedpleasereadtheguideandverifyallpartsarepresentandnotdamaged.Ifanythingismissingordamaged,pleasenotifyPWRPerformanceProductson0755471600.

PACKINGLISTDescription PartNumber QuantityAirInduction55mmColoradoIntercooler PWI64552 1

HotIntercoolerIntakePipe 01.64553 1

ColdIntercoolerOutletPipe 02.64553 1

SiliconeHose51mmx135Degree 15A19105 1

SiliconHumpHose51mmx80mmlong 15A19101 2

SiliconHose62mmx113Degree 15A19104 1

MurryHoseClamps50–73mm TSS36S30EP00C 6

MurryHoseClamps64-86mm TSS40S30EP00C 2

HornSpacers 02A19221 2

M6flatwashers MSFWM6Z 2

BoltM6x25SocketHeadCapScrew SHCSM625ZP 2

BoltM6x10SocketHeadCapScrew SHCSM610ZP 1

Clips-Ducting GM94215211

Decals/LabelsWarrantyCard 1

10


EQUIPMENTANDSUPPLIESREQUIREDFORFITMENT• FenderCover(2)

• 1/4"and3/8"DriveRatchetswithExtensions

• 3/8"DriveTorqueWrench(7-35ft-lbrange)

• MetricSocketSets(shortanddeeprecommended)

• MetricWrenchSets

• MetricAllenKeySet

• T-25,T-27ANDT-30TorxBitScrewdriversorSockets

• ShortPhillips-headScrewdriver

• Smallflatscrewdriver

• TrimPadTool(forpushpinremoval)

• AssemblyLubricant(WhiteLithiumGreaseorPetroleumJelly)

• SharpKnifeorRazorBlade

• Hacksaworsnips(tocutplastic)

• MediumStrengthThreadLocker–Loctite®242(blue)orequivalent

• Writingequipment(penormarker)

• Ziplock/resealablebags(tostoreandlabelremovednuts/boltsclipsetc.)


DISASSEMBLYThefollowingsectionwillguideyouthroughthedisassemblyoftheOEMpartsonyourvehicle.Specialcareshouldbetakentolabelpartsandavoiddamagingitemsasremovedsincemanyitemswillbereused.

1. Openbonnet.2. Coverguardswithfendercoverstoprotect

vehiclefinish.

3. DisconnectBattery.

4. Removeenginecover(Ensureitisfreefromloosedebrisandslideacleanragundertocoverovertheoilfillertoavoidcontaminationofenginewhenremoving)

5. RemovebumperstartingwiththetopedgeofthegrilleusingT15torxandM10socket

6. Nextremovethescrewsunderthewheelwellconnectedthefrontbar.

7. Disconnectfoglightsiffittedatthisstage.

8. UsingaM10andM14socketsundothescrewsunderthefrontlipofthebumper.

Removedebrisandcoverholeasshown


9. Afterallscrewsareundonecarefullyprythebumperusingtrimremovaltool.Itisrecommendedtohaveasecondpersontohelpholdthebartopreventdamagingthebarduringremoval.

10. Undothescrewsholdingthelockpanelcoverandremovethepanel.

11. Removethecoversovertheairbagsensorstogainaccesstotheductingandreinforcementbar.

12. Undothelasttwoboltsinthemiddleofthereinforcementbarandremove.

13. Disconnectandremovethehorns.

14. Removetheductingusingatrimremovaltool.(Breakclipsforspeedyremovalasnewclipsaresuppliedinthekit)

15. Removethelockpanelcoversupportrods.


16. Removethebonnetlatchbraceandunclipthesensorfromthebacksideofthebrace

17. Removebonnetlatchandresttotheside(NOTE-itisrecommendedtotemporarily securewithziptieifrequiredtopreventit slippinganddamagingpanels.)

18. Unboltthelowerreinforcmentbumperbarin4places.(2oneachside)

19. DisconnecttheMAFplug.

20. Undotheintakepipeandremovetheairboxcover.


21. Undothehoseclampsfromthetopoftheintercooler.

22. RemovetheclampsthatretaintheOEMRubberintercoolerpipesfromthesteelhardpipe.Thenundoandremovethesteelhardpipefromtheradiatorcoresupportpanel.

23. Undoandremovethehotpipefromtheturbo.

24. Undoandremovethecoldpipefromthethrottlebody.

25. UnboltandremovetheOEMintercooler.


ASSEMBLYThefollowingsectionwillguideyouthroughtheassemblyofthePWRPerformanceProductsupgradedintercoolerandpipekitinstallationinyourvehicle.

AssemblySection1–Intercooler1. RemovetherubbergrommetsfromtheOEM

intercoolerandplacethemintothePWRintercooler.

2. Installthe2inchsiliconehumphose(Partnumber15A19101)ontotheintercoolerinletandrotatehoseclamparoundasindicatedbeforesecuring.Mirrorthisfortheintercooleroutlet.

3. Reinstalltheintercooleronthecarusingtheoriginalmountingpoints.Takingcaretocarefullyslidetheoutletsthroughtheholesintheradiatorcoresupportpanelbeforethebottompinsarepushedinasitisasnugfit.


4. Reinstallthebonnetlatchandbrace.(NOTE–usetheM6x10mmscrewsuppliedinthekitinthesecondholeofthebraceasindicatedintheimagebelowtoavoidcoredamage.Asthebraceisclosetothecore.Thereshouldbeagapofatleast5mm.)

5. Reinstallairsensorharness.

6. Undotheboltinthecenterofthehornandrotatethebracketaroundsothattheplugsdonothittheintercoolerwhenreinstalled.

7. Screwthehornonwiththealuminiumspacerbehindthebrackettoclearthelipontheradiatorcoresupportpanelandconnectplugs

8. TrimtheductingforboththeleftandrighthandsidesalongtheredlinesasshowntoclearthenewPWRintercooler.

9. Reinstallairductingbyclippingintoplaceusingthesuppliedclips.

Minimum5mmgap

SuppliedM6screw


10. Reinstallthebumperreinforcementpanel,lockpanelsupportsandthelockpanel.

AssemblySection2–PipeKit

EnsuretorquesettingarecorrectforMurryclampstoavoidunderorovertensionofclampswhichmayleadtofailure.RatedUltimateTorque:75in.lbs.min.(8.5Nm)RecommendedInstallationTorque:50in.lbs.(5.6Nm)

11. Installthe135degreesiliconelbowontotheturbo.Slideonhoseclampsbutdonottightenuntilthehardpipeisinstalled.

12. InstallthehotsidePWRhardpipe01.64553intothe135degreeelbowandslipintothe2inchhumphoseontheintercooleratthesametime.

13. Confirmthatthesiliconisharduptotheshoulderonthehoseoutlets,checkclearancesandtightenupallhoseclampsfirmly.

14. ReinstallthefilterboxcoverandcoldairintakebackontothefilterboxbesuretoreconnecttheMAFplug.

MAF Plug


15. Installthecoldpipeandthebyslidingintheintercoolerendfirst.Thenslipthethrottlebodyendofthetubeintopositiontoandrotatesiliconandaluminumpipingtomakesurethatnothingisrubbing.

16. Ensurethesiliconeispushedallthewayontotheribbedoutletandtightenupallhoseclampsfirmly

17. Itisrecommendedtouseasocketthathasauniversaljointandappropriateextensionstogettothehardtoreachhoseclampsbehindtheradiatorcoresupportpanel.

18. NextstepistomovebacktothefrontofthecarandreplacethefrontbumperandGrillcombo.

19. Ensurethatallthelightsarereconnectedbehindthebumperbeforetighteninguplowerfixingscrews.


20. Connectbatteryandconfirmthatallhoses,pipes,wiresandpanelsaresecure.

21. Ensure thatnotoolsorobstructionshavebeenleft underthebonnetandyourPWRIntercooler andpipekitisnowinstalled.

22. Checkalllightsandsensorsthatmayhavebeendisconnectedduringtheinstallarenowfullyfunctional.

23. EnjoyandthankyoufromtheteamatPWR.

Documents

HOLDEN COLORADO (RG) INTERCOOLER KIT...HOLDEN COLORADO (RG) INTERCOOLER KIT ENGINEERING THE UNFAIR ADVANTAGE P/N PWI66175K – INTERCOOLER | P/N PWA64553 (2012-13) – PIPE KIT Contents