$template_hook[AutoInsuranceQuotebox_RON_AUTO]

[DIY] : How to install the Wagner Intercooler
$template_hook[AutoInsuranceQuotebox_RON_AUTO]
  1. Welcome to Kia Optima Forum – General discussion forum for Kia Optima

    Welcome to Kia Optima Forum - a website dedicated to all things Kia Optima.

    You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, at no cost, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, Join Kia Optima Forum today!
     
Page 1 of 4 123 ... LastLast
Results 1 to 10 of 35

Thread: How to install the Wagner Intercooler

  1. #1
    JasonS's Avatar
    Join Date
    Jun 2014
    Location
    Indianapols, IN
    Posts
    3,352
    Year
    2012
    Make
    Kia
    Model
    Optima
    Trim
    EX 2.0

    Arrow How to install the Wagner Intercooler

    So I've been getting a lot of questions about not only the performance behind the Wagner intercooler but also how it installs. This is a guide to help future modifiers if they decide to install the Wagner intercooler.

    My previous thread which contains unboxing information, physical measurements and performance numbers can be found here: https://www.optimaforums.com/forum/6-...tercooler.html

    Just a quick recap. An aftermarket intercooler will provide benefits to anyone who drives a bit more spirited and is definately a must have for anyone with a tuned vehicle. On the dyno we experienced a 10 horsepower gain across the board as well as an increase of torque between 10 and 30 and the Wagner intercooler staying cooler after 4 back to back pulls on the dyno, than 2 with the stock.

    Here's one image that speaks to that. More back on my original thread.



    So how to install the Wagner intercooler.....
    With the Wagner unit, I didnt have to worry about extra piping, clamps, coupler and whatnot, nor pressure drop. This keeps things easy. You first need to remove the front bumper as explained in this thread, http://https://www.optimaforums.com/f...r-removal.html or seen in this video, http://https://www.optimaforums.com/f...val-video.html

    The bumper removal process took me maybe 20 minutes. If you havent done it, probably half an hour.

    Tools you will need here on in are a 12mm socket, 10mm socket, an ratchet extension, flat screw driver, pliers or channel lock type tool.


    With the bumper off, it should resemble my photo you see here. We need to remove the plastic shroud in front of the stock intercooler. It is secured by two 10mm bolts I used with a ratchet extension to remove (red arrows). Once you remove the two bolts, the plastic shroud will be free, but you have to remove the crash guard (bumper) to remove it.

    First ensure you do the following... see the red circled 10mm bolt atop the stock intercooler... remove that bolt, and that bolt only. While you are doing that, also using you pliers or plier type tool, remove the stock clamp securing the flexhose to the top intercooler pipe and pull off the flex pipe from the stock intercooler. You might have to wrestle with it a bit, but dont worry, you're not going to break anything.



    Next up is to physically remove the crash guard (bumper). And this is really easy. It has some weight behind it so I strongly recommend you have someone hold it when you take it off the car. I don't have a picture, but on either side of the crash guard there are (2) 10mm buts and (3) 12mm bolts to remove. They are on pretty good but I was able to break them loose with my ratchet and arm strength. So remove the nuts and bolts on each side and place the crash guard elsewhere until we are ready to remount it.


    Now the plastic shroud falls away and should look similar to this.



    By now I am assuming you have the crash guard off, the plastic shroud off, the top 10MM bolt out, and the top flexhose off the stock intercooler. If you haven't already, the piece of metal the top 10MM bolt secures will rotate out of the way, freeing up the top of stock intercooler.



    That leaves one more connection to undo and it was the most difficult for us; the bottom hose connector. The difficulty was in accessing it as you need a sufficiently long enough pair of pliers, but also once the stock hose clamp was removed, my hose stuck like glue to the intercooler pipe. This is where I had to use some muscle and the flat side of a screw driver to pry away the hose from the intercooler pipe. You access this area from the drivers side of the stock intercooler. There is a small window where you can get a hand or two in to remove the stock IC clamp and remove the flexhose from the IC. Once you separate the hose from the stock IC, the stock IC just lifts and pulls out from the front.



    Here are the two IC's laying next to each other. You can see the more massive size of the Wagner. Here you will want to grab the (3) rubber grommets off the stock IC and place them on the same spots on the Wagner IC. If you seem to be "missing" a grommet or two like I was, my two lower grommets were still in the holes in the car frame. I just grabbed them from there and placed them onto the Wagner.



    Here is a shot of my lower pipe connection on my stock IC (cold side). Several people worry about oil accumulation and this picture shows no "pool" of oil after 60,000 miles, however, you can indeed see there is a oil coating on the piping. Just for information and to dispel oil pool rumors.



    Now you just start reversing all your steps. Make sure the 3 rubber grommets are on the Wagner intercooler mount points. Insert the bottom of the Wagner intercooler first and slide in the top. I had to shimmy mine in as its a pretty tight fit as you can imagine. I did have to make one adjustment at the bottom as seen in this picture. The wire for the stock horn is in some wire loom that is zip tied to some mounting clips. Because of the tight tolerances, this half inch obstruction created an obstacle. All I did was snip the zip tie and move the wiring loom beneath the plastic mount point as seen in the picture. Takes but a moment and really makes it easy to slide the Wagner into place.



    Once you have completed that step and the intercooler is in place, your front end should look like this picture.


    Next step is to secure the top of the intercooler (this will aid in connecting the bottom flex hose). Rotate the piece of metal with the upper grommet socket that was unhinged earlier and refasten with the 10mm bolt. Reconnect the upper flex pipe to the intercooler and secure with the factory clamp or (if you bought) an upgraded worm drive or T-bolt clamp. Don't forget to clamp!



    Lastly, tackle the bottom flex hose connection to the intercooler. Again enter the gap from the driver side of the intercooler. you should be able to wiggle the flex hose onto the intercooler pipe connector and then secure it with the factory clamp, or an upgraded worm or T-bolt clamp if you went that route. Its a LOT easier going on then it was coming off. Make sure your clamp is tight!



    Now put the crash bar (bumper) back on. Again its easier with two people at this point due to the height and length of the crash bar. It goes back on with (2) 10mm nuts and (3) 12mm bolts. Tighten by hand really good.



    Here is just a top down look at the Wagner IC installed compared to the surrounding metal and crash guard.


    You are all complete at this point. Reattach the front bumper cover. Make sure all tools and bolts and plastic clips are accounted for. The only things you should have left over is the stock intercooler, the plastic shroud and (2) 10mm bolts. If that's what you have, you are good. Enjoy the extra performance!
    Last edited by JasonS; 04-16-2015 at 09:40 AM.
    Dynojet: 294 whp/305 torque/24lbs boost with a custom BTR tune with full bolt-ons.
    2012 Optima EX-T Spicy Red Showroom https://www.optimaforums.com/forum/4...-showroom.html w/ the following MODs: 845 Motorsports FMIC|845 Motorsports 4" Intake|845 Motorsports Charge Pipe|Nameless Midpipe|Nameless Downpipe|Synapse V3 BOV|BTR Custom Tune|Magnaflow Exhaust|Saikou Michi OCC's|Ultra Racing FSTB|kSport Coilovers|R1 Concepts rotors|and MORE...

  2. The Following User Says Kudos to JasonS For This Useful Post:


  3. Remove Advertisements
    Optima Forums
    Advertisements
     

  4. #2
    Your K5 Optima Vendor K5 Optima Store's Avatar
    Join Date
    Dec 2011
    Location
    Chatsworth, CA
    Posts
    27,792
    Year
    2017
    Make
    Tesla
    Model
    Model X
    Trim
    P100D
    Jason, wow! This is a fantastic write up and review. I think this will work out great for any members interested in doing the FMIC swap. Thank you for taking the time to put this together for the community.

    We have a group buy running currently on the forum here for any members interested in saving some money on the Wagner Intercooler. Details of the group buy can be found below:

    https://www.optimaforums.com/forum/12...ima-store.html





  5. #3
    OptimaForums Veteran Triple-K.Hybrid's Avatar
    Join Date
    Aug 2013
    Location
    Louisiana
    Posts
    3,606
    Year
    2012
    Make
    KIA
    Model
    Optima HYBRID
    Trim
    Personalized ^_^V
    Thats an awesome upgrade and write up brotha

    Visit My 2012 BAGGED HYBRID's Showroom
    Check out my UNDERNEATH Lights VIDEO here https://www.optimaforums.com/forum/49...owroom-36.html
    Rear Seat Removal DIY https://www.optimaforums.com/forum/49...owroom-32.html



  6. The Following User Says Kudos to Triple-K.Hybrid For This Useful Post:


  7. Remove Advertisements
    Optima Forums
    Advertisements
     

  8. #4
    JasonS's Avatar
    Join Date
    Jun 2014
    Location
    Indianapols, IN
    Posts
    3,352
    Year
    2012
    Make
    Kia
    Model
    Optima
    Trim
    EX 2.0
    Quote Originally Posted by K5 Optima Store View Post
    Jason, wow! This is a fantastic write up and review. I think this will work out great for any members interested in doing the FMIC swap. Thank you for taking the time to put this together for the community.
    Quote Originally Posted by Triple-K.Hybrid View Post
    Thats an awesome upgrade and write up brotha
    Thanks guys. Hope this helps folks regardless of which IC they end up with.
    Dynojet: 294 whp/305 torque/24lbs boost with a custom BTR tune with full bolt-ons.
    2012 Optima EX-T Spicy Red Showroom https://www.optimaforums.com/forum/4...-showroom.html w/ the following MODs: 845 Motorsports FMIC|845 Motorsports 4" Intake|845 Motorsports Charge Pipe|Nameless Midpipe|Nameless Downpipe|Synapse V3 BOV|BTR Custom Tune|Magnaflow Exhaust|Saikou Michi OCC's|Ultra Racing FSTB|kSport Coilovers|R1 Concepts rotors|and MORE...

  9. #5
    Learner's Permit GreyOps's Avatar
    Join Date
    Sep 2013
    Location
    Largo, Florida
    Posts
    117
    Year
    2013
    Make
    Kia
    Model
    Optima
    Trim
    SXL
    Great write up JasonS! I was wondering how the hell one replaces the intercooler . You covered everything.

  10. #6
    JasonS's Avatar
    Join Date
    Jun 2014
    Location
    Indianapols, IN
    Posts
    3,352
    Year
    2012
    Make
    Kia
    Model
    Optima
    Trim
    EX 2.0
    Quote Originally Posted by GreyOps View Post
    Great write up JasonS! I was wondering how the hell one replaces the intercooler . You covered everything.
    Know everyone knows! Lol. Thanks. Its not as hard or lengthy as people think.
    Dynojet: 294 whp/305 torque/24lbs boost with a custom BTR tune with full bolt-ons.
    2012 Optima EX-T Spicy Red Showroom https://www.optimaforums.com/forum/4...-showroom.html w/ the following MODs: 845 Motorsports FMIC|845 Motorsports 4" Intake|845 Motorsports Charge Pipe|Nameless Midpipe|Nameless Downpipe|Synapse V3 BOV|BTR Custom Tune|Magnaflow Exhaust|Saikou Michi OCC's|Ultra Racing FSTB|kSport Coilovers|R1 Concepts rotors|and MORE...

  11. #7
    01/2015 ROTM
    05/2015 ROTM
    Julio Kia's Avatar
    Join Date
    Feb 2014
    Location
    Bradenton FL
    Posts
    1,137
    Year
    2013
    Make
    Optima
    Model
    2013 SXL
    Trim
    "Modified"
    Great DIY Jason !!..well done.....now clean that darn engine bay !!!!

  12. #8
    Riding Lawn Mower
    Join Date
    Dec 2014
    Posts
    92
    Year
    2011
    Make
    kia
    Model
    sx
    Trim
    sx
    Nice job Jason good

  13. #9
    JasonS's Avatar
    Join Date
    Jun 2014
    Location
    Indianapols, IN
    Posts
    3,352
    Year
    2012
    Make
    Kia
    Model
    Optima
    Trim
    EX 2.0
    Quote Originally Posted by jamesbaker1975 View Post
    Nice job Jason good
    Thanks for the help James. Glad you were able to come down, the extra hands became handy!
    Dynojet: 294 whp/305 torque/24lbs boost with a custom BTR tune with full bolt-ons.
    2012 Optima EX-T Spicy Red Showroom https://www.optimaforums.com/forum/4...-showroom.html w/ the following MODs: 845 Motorsports FMIC|845 Motorsports 4" Intake|845 Motorsports Charge Pipe|Nameless Midpipe|Nameless Downpipe|Synapse V3 BOV|BTR Custom Tune|Magnaflow Exhaust|Saikou Michi OCC's|Ultra Racing FSTB|kSport Coilovers|R1 Concepts rotors|and MORE...

  14. #10
    Learner's Permit
    Join Date
    Jun 2014
    Location
    CERES, CA
    Posts
    193
    Year
    2015
    Make
    KIA
    Model
    OPTIMA
    Trim
    SXL
    What size t bolt clamp is used?

  15. Remove Advertisements
    Optima Forums
    Advertisements
     

Page 1 of 4 123 ... LastLast

Similar Threads

  1. [VENDOR][FS]: Wagner Tuning Performance Intercooler - K5 Optima Store
    By K5 Optima Store in forum K5OS - Performance
    Replies: 118
    Last Post: 06-21-2019, 03:30 PM
  2. Bought a Wagner Intercooler
    By JasonS in forum Optima Engine and Technical Discussion
    Replies: 116
    Last Post: 06-16-2016, 04:10 PM
  3. Wagner vs. CX Racing Intercooler
    By Marcel13 in forum Optima Engine and Technical Discussion
    Replies: 7
    Last Post: 04-22-2015, 07:57 AM
  4. Wagner Tuning Intercooler
    By BigDPolock in forum Optima Engine and Technical Discussion
    Replies: 40
    Last Post: 02-14-2015, 06:35 AM
  5. Wagner Tuning Stock Placement Intercooler
    By Horn Dog in forum Optima Engine and Technical Discussion
    Replies: 46
    Last Post: 02-01-2015, 09:17 PM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Powered by vBadvanced CMPS v4.3.0