Intercooler Installation Manual Audi RS4

Intercooler Installation Manual Audi RS4

Step 1 – Remove Headlights. Remove the two T30 Torx screws from the top of the headlight, and the one side T30 Torx screw through the access port in the fender. Step 2 – Remove Bumper Cover. Remove the two side grille inserts from the front bumper. Remove the two 6mm Allen bolts from the bumper support brackets. Step 3 – Remove Hardware from Radiator Support. Remove four (two per side) upper T30 bolts. Step 4 – Remove Stock Intercooler Hose Clamps. Loosen hose clamps from upper intercooler hoses on the side of the plastic inlet pipes (or BiPipe).

Step 5 – Remove Stock Intercoolers. Remove the stock intercoolers from the car with the stock hoses attached. To do this, lift up on the intercooler and slide the intercooler towards the front of the car. Step 6 – Remove Drivers Side Intercooler Bracket. Remove the drivers side intercooler bracket by using a ¼” drill bit. Step 7 – Move and Remount Horns. Remove horns from either side of car. Reroute horn wiring harness behind headlights. Step 8 – Trim Intercooler Shrouds. Unbolt the intercooler shrouds from the stock intercoolers. Trim the side off of the shrouds as shown by the dotted lines. Step 9 – Install Hose Clamps and Hoses on RS4 Intercoolers. Do not use any type of lubricant on the inside of the hoses to ease installation. Step 10 – Cutting Fender and Radiator Support. Cover all open inlet pipes with a rag and then trim the fenders on either side as shown by the dotted lines. Step 11 – Install Intercoolers in Car. Slide the RS4 intercoolers into position in the car using the same method that was used to remove the stock intercoolers. Step 12 – Install Remaining Intercooler Hose Clamps.