Guide: HDI FMIC (front mount intercooler)

[Paul_13]

As promised 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-R...588f1c007b

Intercooler : http://www.txautosport.co.uk/universal-m...-428-p.asp

57mm x 600mm alloy pipe x1: http://www.ebay.co.uk/itm/57mm-Straight-...56545571e7

54mm rubber lined clips x2/3: http://www.ebay.co.uk/itm/RUBBER-LINED-M...1c48f5a066

57mm 180' bend x1 : http://www.ebay.co.uk/itm/ASH-180-Degree...2ecae75823

51mm x 57mm Reducer 90's x 3: http://www.ebay.co.uk/itm/NEw-Silicone-H...339105b2e9

51mm 90' alloy x 2: http://www.ebay.co.uk/itm/2-90-Degree-30...2eca987f45

51mm 90' silicone x1 : http://www.ebay.co.uk/itm/New-Silicone-9...0886048856

51mm silicone joiner x1: http://www.ebay.co.uk/itm/150mm-Long-x-S...27c06a536e

51mm alloy pipe 1M : http://www.ebay.co.uk/itm/51mm-2-Alumini...1e6723f5b6

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]

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

[Eeyore]

ah man. wish I had a hdi to do this on now! Ive got some of the bits already!

[Paul_13]

I'll do an updated post when I got the improved hoses on

[Poodle]

Good guide, makes a nice change for something to show a lot of the potential issues too.

More useful information here:

http://306oc.co.uk/forum/showthread.php?tid=43

---

Worth merging, mods?

Should probably also point out this is only one way of doing it, there's probably about 5 different easy options that i can think of and what you do is all down to your particular installation and personal preferences.

[allanallen]

Nice guide Paul, a lot better than the others I've seen

[Paul_13]

Cheers

EDIT: Updated pipes added and pictures amended

[ashdturb]

What differences is there to the xud I'm fitting one to mine do I still need the 406 manifold and turbo pipe ? Or can I use the pug one or a xantia manifold ?

[Poodle]

Xud is completely different.

[Josh_Quant]

Good guide loads of useful photos as well..

In the second picture down with 406 top hose how long is the meter joiner between top hose 406 and 51mm 90degree?

Thanks josh

[Poodle]

From the picture that looks to be about 25cm.

[Paul_13]

I'll measure when I get a chance

[Josh_Quant]

Ideal thanks

[Paul_13]

230mm

[Josh_Quant]

Ideal cheers Paul

[JTaylor2005]

I have just found this one here

http://www.ebay.co.uk/itm/Brand-New-Inte...Swd0BVwGRa

Do you reckon that would fit well in front of the radiator and those pipes would then go down the side of the rad?

Thanks

[markos_7772]

Hello! Wich is the diameter of the bottom turbo pipe and the top hose from the 406 HDI? Im gonna made them by my own because its difficult to find then here..