306 Hdi Front Mount Intercooler Guide

[Paul_13 212 1 Cars]

Here's the guide for fitting a FMIC to a Peugeot 306 hdi . This is just the way I have done it, there are other ways of doing it etc.

 

Bits you'll need:

 

Jubilees: 60-70mm & 50-60mm

 

8mm threaded rod & 8mm nuts: http://www.ebay.co.uk/itm/Threaded-8mm-Rod-Studding-Bar-Zinc-Plated-M8-x-1000mm-/380358099067?pt=LH_DefaultDomain_3&hash=item588f1c007b

 

Intercooler : http://www.txautosport.co.uk/universal-medium-fmic-tube--fin-design-600mm-x-180mm-x-60mm-with-57mm-inlets-428-p.asp

 

57mm x 600mm alloy pipe x1: http://www.ebay.co.uk/itm/57mm-Straight-600mm-Length-Alloy-Pipe-For-Intercooler-Silicone-Rubber-Hose-/370782073319?pt=LH_DefaultDomain_3&hash=item56545571e7

 

54mm rubber lined clips x2/3: http://www.ebay.co.uk/itm/RUBBER-LINED-MUNSEN-RING-ANTI-VIBRATION-M8-M10-PIPE-CLIPS-PIPE-RINGS-/121483141222?pt=LH_DefaultDomain_3&var=&hash=item1c48f5a066

 

57mm 180' bend x1 : http://www.ebay.co.uk/itm/ASH-180-Degree-Silicone-Silicon-Hose-Elbow-Bend-Rubber-Coolant-Radiator-Pipe-/200972654627?pt=LH_DefaultDomain_3&var=&hash=item2ecae75823

 

51mm x 57mm Reducer 90's x 3: http://www.ebay.co.uk/itm/NEw-Silicone-Hose-90-Degree-Reducer-Silicon-Rubber-Elbow-Reducer-2-Hose-Clips-/221476401897?pt=LH_DefaultDomain_3&var=&hash=item339105b2e9

 

51mm 90' alloy x 2: http://www.ebay.co.uk/itm/2-90-Degree-300mm-Length-Alloy-Pipe-For-Intercooler-Silicone-Rubber-Hose-/200967487301?pt=LH_DefaultDomain_3&var=&hash=item2eca987f45

 

51mm 90' silicone x1 : http://www.ebay.co.uk/itm/New-Silicone-90-Degree-Elbow-Hose-Silicone-Pipe-Bend-Water-Air-2-Clips-to-suit/221436193655?_trksid=p2045573.c100034.m2102&_trkparms=aid%3D555012%26algo%3DPW.MBE%26ao%3D2%26asc%3D29666%26meid%3D531fc651b2274c2bba7d2d7d8bd850d1%26pid%3D100034%26rk%3D2%26rkt%3D4%26sd%3D190886048856

 

51mm silicone joiner x1: http://www.ebay.co.uk/itm/150mm-Long-x-Silicone-Hose-Coupling-Connector-Pipe-Silicon-Rubber-Joiner-Coupler-/170731918190?pt=LH_DefaultDomain_3&var=&hash=item27c06a536e

 

51mm alloy pipe 1M : http://www.ebay.co.uk/itm/51mm-2-Aluminium-Alloy-Tube-Hose-Pipe-Tube-Silicone-Rubber-Intercooler-1-Metre-/130579428790?pt=LH_DefaultDomain_3&hash=item1e6723f5b6

 

Lower boost pipe:

 

406 110 top hose (l shaped hose)

 

 

C5 all metal (preferably) inlet pipe

 

 

 

Installation guide:

 

First off remove the bumper: http://306oc.co.uk/forum/showthread.php?tid=7361

 

Remove the fan cowling as you need to make room for the front mount intercooler

 

 

Remove the TPS from the air box, flip the bracket and drill a hole on the slam panel:

 

 

Setup the intercooler like so: (i trimmed down the 180 hose a smidge and made a double sided clip)

 

 

I fixed the intercooler through the bottom panel and locked off the stud:

 

 

Drilled a hole in the slam panel and put a bit of 8mm rod through.

 

IC is solid and doesn't move now.

 

IC sits dead central and the hoses either side needed trimming 10mm

 

Just to note I have kept the radiator in the standard position

 

 

 

The only bit that needed modifying was the slam panel. It needed pulling towards the front bumper a little to clear the 180 degree hose

 

 

 

Pic of the pipes down the side (51 x 57 reducer 90's)

 

 

 

 

Where they lead to. The top hose needs trimming down a tad.

 

 

 

 

 

The cold air feed is retained

 

 

 

I cut a bit off the 406 top pipe, this ends up being 2" when you do so

 

 

 

The old inlet elbow and air doser removed

 

 

 

 

Where it came from

 

 

This was an absolute twat to remove, easiest way was a hacksaw after undoing the jubilees, one on the turbo (accessible from the wheel arch) and one on the inlet elbow/air doser (accessible from under the car through the exhaust tunnel)

 

 

Very restrictive design down to around 1" in places

 

 

 

New all alloy inlet elbow

 

 

[Paul_13 212 1 Cars]

Here's the bottom turbo pipe, a thanks to Allanallen on this one. The pipe is not a direct fit!

 

 

Here's the bits you need to trim

 

 

 

The part of the subframe that needs relieving (I was in a rush so this could be done neater )

 

 

Turbo pipe fitted. The PAS pipe gets right in the way

 

 

Off of the above pipe you want to install the last 51/57mm reducer 90, then a short bit of pipe, the 51mm joiner and the last 51mm alloy 90 to bring you back to the intercooler (pictured bottom right ^)

 

 

All back together! My air duct bolt had sheared off hence the cable tie

 

 

Nice and subtle

 

 

Make sure you nip everything up.

 

Just to note I cut my own 2" pipes as buying them precut and beaded was going to be expensive.

I haven't beaded my pipes but i've yet to have a hose blow off