ETS 2G DSM Front Mount Intercooler

Installation Instructions
Congratulations on your purchase of the finest Front Mount Intercooler Kit available for the 2G
DSM. Every aspect of this kit has been engineered with performance, fitment, and ease of
installation in mind. We recommend that a competent automotive performance shop complete the
intercooler installation, but the following instructions will be helpful if you are doing the installation
yourself. The piping in this kit will go from the turbo outlet and the throttle body elbow to each side
of the intercooler. This kit is modular, taking only one pipe to upgrade your turbo.
1. Remove: headlights (figures 1- 5), corner lights (figures 6-8), bumper (figure 9-14), bumper
support (figures 15-17), fog lights (figures 18-22), stock intercooler (figures 23-30), all
related piping (figure 31), and splash guards (figures 32-36). Please refer to the stock service
manual for these steps.
Tip: The headlights on the 2G are very hard to get out, there is a lower bolt that is
very hard to locate. It is on the bottom of the headlight, and can be loosened by using
a socket on a long extension, with a universal joint, going in through the air ducts by
the fog lights.
2. The power steering cooler line will be removed. Use the stock rubber line that comes off the
power steering tank, and loop it back into the exposed power steering line once the PS
cooler line is removed from the front of the car. This will complete the power steering
circuit. (See figures 37-43)
3. ***This step is optional but recommended. Following this step will allow the intercooler to
sit further back under the bumper support. The further back the intercooler sits, the less
bumper trimming is needed. ***
Using a hammer, flatten out the core support post that runs up to the hood latch.
Only flatten the lower portion of the post. (Figure 44)
4. Now we recommend using a jack to hold the intercooler up to the bumper support, and then
center the intercooler to the bumper support using a tape measure (Figure 45-46). Make sure
the IC is sitting as far back as possible, usually to 1 off the lower core support.
5. Drill holes and attach the intercooler to the bumper support (Figure 47).
6. Mock up the bumper cover to make sure the intercooler is centered (Figure 48).
7. Some bumper cover trimming will be required; the picture is of a 97 Eclipse (Figure 49).
8. This step is for those with the stock T25 or a T28 turbo; the lower passenger fan bracket
must be cut for the T25 piping. We recommend a reciprocating saw for this, but a hacksaw
blade will work. Please see (Figures 47-53).
9. Connect the T25 piping to the turbo and replace fan (Figures 54-55).

10. Now the driver and side splash guards will be trimmed so the piping can wrap around to the
intercooler (Figures 56)
11. Now install the large U shaped pipe, connecting it with the T25 pipe that is bolted to the
turbo. The short side goes to the intercooler (Figures 57-58)
12. Install one of the 2.5 Couplers on the throttle body elbow, use the one smaller clamp which
should say 2.50 on it, to seal this hose to the elbow (Fig 59)
13. Install the TB pipe and connect it to the throttle body elbow (Fig 60)
14. Now install the 45 degree pipe and connect it to the bottom of the TB Pipe (Figure 61)
15. Cut the passenger side splash guards to allow the piping to go into the engine compartment
(same as figure 56). This is where the 45 degree pipe and banana pipe will meet.
16. The banana pipe will be installed below the 45 degree pipe, connecting with the left side of
the intercooler.
17. Tighten all clamps, and make sure all piping is secure.
18. Install MAS and intake (Figure 62)
19. Re-Assemble vehicle

10 IC Supplement
If you ordered our 10 unit, we include 2 brackets that will need to be trimmed to fit, as the
holes in the core support change from year to year. You will also need to cut out the back side of the
bumper support.

T3/T4 Supplement
If you ordered a T3/T4 piping kit, the turbo outlet must face straight down. The T3/T4 pipe
will connect directly to the large U shaped pipe on the driver side
For technical assistance or warranty issues please contact us
Extreme Turbo Systems
360-263-3748

Figure 1

Figure 2

Figure 3

Figure 4

Size 10

Size 10

Size 10

Size 10

Figure 8

Figure 5

Figure 6

Figure 7

Remove light

Pop out light

Remove light bulb

Figure 9

size 10 5 bolts on top

Figure 10

Figure 11

Figure 12

Remove

Remove pin with a

Remove pin

Figure 13

Figure 14

Figure 15

Figure 16

Pull back splash guard

Size 10- along

Remove bolts on top of

Remove nuts on bottom

Figure 17

Figure 18

Figure 19

Figure 20

Remove nuts

Top left- remove fog

Bottom left size 10 &

Right- Phillips

Figure 21

Figure 22

Figure 23

Figure 24

Pull fog light out

Size 10

Size 10

Size 10

Figure 26

(repeat 18-21 for other fog light)

Figure 25

Figure 27

Figure 28

Remove connected
intercooler piping

Pull back splash guard

Pull back splash guard

Remove piping at top of

Figure 29

Figure 30

Figure 31

Figure 32

Remove related piping

Remove splash guardscrews at top

Remove intercooler duct

Figure 32

Figure 33

Remove screws along

Remove screws along

Figure 36

Figure 37

Move clip on PS linetop of engine bay

Figure 34

Figure 35

Figure 39

Figure 38

Unbolt PS line on topsize 12

Unbolt PS line on top

Figure 39

Figure 40

Figure 41

Figure 42

Unbolt PS line on
bottom- size 12

Reroute line (caution:

This is what the

Flatten out core support

Figure 43

Figure 44

Figure 45

Figure 46

Use a jack to hold up IC

Use a tape measure to

Drill holes & attach IC

Mock up bumper

Figure 49

Figure 47

Figure 48

Figure 49

Remove fan 4 bolts

Figure 50

Figure 51

Figure 52

Figure 53

Cut off lower passenger

Figure 54

Figure 55

Figure 56

Figure 56

Attach T25 piping to

Reattach fan

Trim splash guards

Install the U shaped

Figure 57

Figure 59

Figure 60

Figure 61

Attach U pipe to
intercooler

Use small coupler on

Attach the TB pipe

45 degree pipe attached

Figure 62

Install MAS and intake

Figure 63

Figure 64