Ok, a little how to on the Perrin FMIC install. As you will notice it doesn not come with instructions but it isn't too difficult. This "How to" is just designed to make it easier and to try and avoid any potential pitfalls.
You will need some tools/equipment:
-Flat black spray paint
-Rubber/Mallet hammer
-A socket wrench and sockets sizes 8mm,10mm,12mm,13mm,14mm
-Lots of extensions for the socket wrench. It will just make the job easier.
-Assorted allen keys. I'm not sure what size it is, but you'll need one of the smaller ones.
-Optional!! I am going to get some 2.5" Turbonetics "t-bolt clamps" These would allow you to tighten the intercooler intake/exit pipes tighter than the common style from the factory.
-An extra person will make the install much easier
Ok, lets get started. If your car is lowered you'll need a floor jack and jack stands. If it is still riding at stock height you won't need it at all.
Step-1 start by opening the hood and letting the car cool off a bit. You'll be working around the engine bay so it will get hot quick.
Step-2 Get out that 8mm socket and wrench and begin removing the top (3) 8mm bolts that hold down the bumper. After finishing w/ that. You'll need to get underneath the car to remove the (5) 8mm bolts that connect the bumper to the underside of the vehicle. See picture below for location of bolts.
Step-3 Next thing you'll need to do is loosen and remove the hex/allen key type fasteners on the front of the wheel well. There are 2 on each side.
Step-4 After removing the allen key fasteners, you will need to carefully pull the bottom corner of the bumper to get the black fenderwell lining on the outside. Doing this will give you access to the foglight bulbs, and corner lense bulbs which should be removed next.
Step-5 Now you should be able to look underneath the bumper(providing your head isn't too big) to locate the fog light bult and corner lense bulb. You will need to disconnect those. The corner lense is removed by just turning it back and forth. The fog light bulb is held in by a retaining clip. Just use your thumb to pry the clip loose. (See illustration below)
Step-6 Now that you have removed all the 8mm bolts and pulled away the bulb's from their harnesses, you have to remove (3) 10mm bolts on each side of the car which connect the bumper cover to the fender. Because you have pulled the fenderlining out of the front bumper cover, they should be fairly easy to access. This is where your multiple extensions will be very handy. See the picture below.
Step-7 The bumper cover is ready to be removed but might still provide some resistance. It is because of the bolts that connect the fender to the bumper cover(the ones in step 6) are at an angle and are still holding it on. Gently massage it off of the car and put face up or lay on a sheet to avoid scratching the bumper cover. (I set mine aside in the grass)
Step-8 Now you are ready to remove the OEM bumper support.Start by removing the black foam cover to the bumper support. It is held on by 2 plastic fasteners which you will not need later. The actual is fastened to the car with (6) 13mm bolts.
It is imparative you remove these bolts in a certain order. The reason being is that you may strip out some of the bolts cause it's held on by pressure as well. Ok, start by removing the top and bottom bolts first. After you do that you will be ready to remove the front two. You will notice as you are removing the front two bolt is will start to back out with you. This is where a friend comes in handy so that the weight of the support does not strip the bolts as you will need them later upon reinstallation.
Step-9 Ok, you are ready to start removing the intercooler. Start by removing the rubber hoses connected to the endtanks of the intercooler. You can use the 8mm wrench to do this. If you end up using the flathead screwdriver you will more than likely strip it out. Before you can remove those though, there are some staples in the rubber hose to prevent it from shifting around. Remove those first and proceed to loosen the intercooler hoses. The passenger side hose(intake side) is especially difficult to access. My hose clamp was located right inbetween the radiator and the chasis. There is a 12mm bolt right underneath where the hose follows to the intercooler. Removing this bolt will make it easier to get to. The illustration below of the exit side of the intercooelr shows you what you should be looking for.
Step-10 Now that your intercooler hoses are loose, you can begin removing the (4) 12mm bolts that attach the intercooler to the chasis. There are two bolts on each side. Once they are removed you can remove the old intercooler.
See illustration below:
Step-11 Upon removing the intercooler/bumper support assembly you will notice alot of unfinished/or unpainted areas that will now be exposed. See pictures below for reference:
Now look at the difference when you paint them.
Step-12 You are pretty much ready to reinstall the new intercooler. Don not tighten the bolts that go to the bumper support or the ones that mount the intercooler to the bumper support. Make sure they are hand tight as you will need to move and shift the intercooler when trying to get the rubber intercooler hoses connected. You will only need to connect the front 2 support bolts now anyway. I will show you the rest in a second.
Step-13 When re-connecting the intercooler intake/exit hoses the passenger side(intake side) one will be even more difficult for 2 reasons. (1) The area is confined . (2) The new intercooler pipe is now round instead of oval so there is less room to work. I ended up loosening the (2) 10mm radiator support brackets. After you loosen them you can turn them around, they don't have to be compelety removed. This will give you the abiltiy to make a little room where the second person comes in handy again.
Step-14 When you have connected the intake/exit sides of the intercooler you are ready to secure your new bumper supports. To properly be able to do this you will need to access the top bolt for the new bumersupport which now resides underneath the headlights. There are 2 really long 8mm bolts that affix the headlamp to the chasis. Go ahead and pull those completely off.
See Illustrations:
In the picture above you can see the only way you are going to get to the bulb above the headlight is to remove it.
Step-15 Your intercooler is mounted and connected. On the underside of the intercooler you will notice 2 bolts. I assume they are there to fasten the the black cover underneath the intercooler. Mine didn't quite lineup so I just punched a new set of holes through the black plastic.
Step-16 Now would be a good time to go and test the intercooelr for leaks. Take it for a drive, make sure you secure the lighting fixtures if you are going to do so. Otherwise just give it a start and listen for leaks.
That is it guys, reverse the process to reinstall the bumper. You are all finsihed. If I have left out any steps or provided some misinformation please PM me so that I can edit it so it makes it easy for the next person. Enjoy, I hope it was of great help to you. Oh, and if you are wondering why I listed the hammer in the tools needed to do the installation. I always have one in case I get frustrated.
