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Street Series Intercooler Kit [INTK5002 : -BL] Instructions

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PRO <strong>Series</strong><br />

<strong>Intercooler</strong> <strong>Kit</strong><br />

Ford ranger raptor P703 / RA 2022-<br />

<strong>INTK5002</strong><br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS


INSTALLATION MANUAL<br />

IMPORTANT<br />

Please read this manual in it’s entirety before proceeding with the installation of the intercooler kit. This Fenix<br />

Pro <strong>Series</strong> <strong>Intercooler</strong> kit is only designed for the vehicles outlined below and may require modifications If your<br />

setup differs from factory.<br />

COMPATIBILITY<br />

• 2022- Ford Ranger Raptor P703 / RA 3.0L 6cyl turbo petrol.<br />

KIT FEATURES<br />

• Dyno tested to decrease IAT’s up to 20°C.<br />

• Increased capacity of 37.5% [<strong>Intercooler</strong>].<br />

• Bar & plate construction with temperature efficient inner fin design.<br />

• Dual 50mm inlet & 63mm outlet.<br />

• CNC fixtures for factory fit of OEM BOV, air temperature sensor & air recirculation pipe.<br />

<strong>INTK5002</strong><br />

Professional installation is recommended. Removal of the factory intercooler shroud is required.<br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS


PARTS LIST<br />

Ensure all parts listed below are accounted for prior to commencing installation. Fenix is not liable for any<br />

damage to your vehicle due to incorrect installation, neglect or in-proper use. Fenix recommends that a mechanic<br />

or trained professional install Fenix Performance products.<br />

[A] <strong>Street</strong> Pro <strong>Series</strong><br />

<strong>Intercooler</strong> - x1<br />

[B-1] Alloy<br />

<strong>Intercooler</strong> Pipe - x1<br />

[B-2] Alloy<br />

<strong>Intercooler</strong> Pipe - x1<br />

[B-3] Alloy<br />

<strong>Intercooler</strong> Pipe - x1<br />

[B-4] Alloy<br />

<strong>Intercooler</strong> Pipe - x1<br />

[B-5] Alloy<br />

<strong>Intercooler</strong> Pipe - x1<br />

[B-6] Alloy<br />

<strong>Intercooler</strong> Pipe - x1<br />

[C-1] Silicone Joiner<br />

63mm - x2<br />

[C-2] Silicone Joiner<br />

63mm > 70mm - x1<br />

[C-3] Silicone Joiner<br />

51mm - x4<br />

[D-1] Hose Clamp<br />

60mm > 80mm - x1<br />

[D-2] Hose Clamp<br />

50mm > 70mm - x5<br />

[D-3] Hose Clamp<br />

40mm > 60mm - x8<br />

[E] M6 x 10mm Bolt<br />

- x2<br />

[F] M6 Bolt x 15mm<br />

- x1<br />

[G] M6 Washer - x3<br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS


STEP 1.<br />

INSTALLATION<br />

Disconnect the battery. Following this, remove the factory bash plate, intercooler and piping. For full<br />

instructions see your vehicles user manual or seek a professional.<br />

Fig. 1 Fig. 2<br />

STEP 2.<br />

Remove the rubber mounting bushes from the factory intercooler and transfer them to the Fenix Pro <strong>Series</strong><br />

<strong>Intercooler</strong> [A] - Fig 3. Following this, fit the Fenix Pro <strong>Series</strong> intercooler [A] into the factory location - Fig 4.<br />

Fig. 3<br />

Fig. 4<br />

Change the x2 front OEM intercooler shroud bolts to the included M6 x 10mm bolts [E] . Failure to change these bolts may cause<br />

damage to the Fenix Pro <strong>Series</strong> <strong>Intercooler</strong>. Note: This kit does not utilize the OEM rear intercooler shroud.<br />

STEP 3.<br />

Remove the OEM blow-off-valve [BOV] from the factory upper hot pipe located on the passenger side - Fig 5.<br />

Transfer the BOV to the alloy intercooler pipe [B-1] utilizing the OEM mounting studs - Fig 6.<br />

Fig. 5 Fig. 6<br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS


STEP 4.<br />

INSTALLATION<br />

Install the upper intake alloy intercooler pipe [B-6] as pictured in Fig. 7 utilizing the silicone joiner [C-2] and hose<br />

clamps [D-1 / [D-2] to attach it to the throttle body. Following this, bolt the pipe to the block utilizing the OEM<br />

hardware and reconnect the OEM sensors as pictured in Fig. 8 utilizing the supplied hardware [F / G] .<br />

Fig. 7 Fig. 8<br />

We recommend you install the hose clamps loosely to ensure correct alignment throughout the system prior to a final tighten.<br />

STEP 5.<br />

Install the lower intake alloy intercooler pipe [B-4] utilizing the silicone joiners [C-1] and hose clamps [D-2] to attach<br />

to the Fenix Pro <strong>Series</strong> intercooler and upper intake pipe - Fig. 9 / 10.<br />

Fig. 9 Fig. 10<br />

STEP 6.<br />

Install the upper hot alloy intercooler pipe [B-5] located on the driver side - Fig. 11, utilizing the OEM rubber<br />

turbo outlet and clamp - Fig. 12.<br />

Fig. 11 Fig. 12<br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS


INSTALLATION<br />

Following this, ensure the upper hot pipe is secured to the OEM mounting position utilizing the OEM<br />

hardware ] and the coolant lines are secured to the mounting brackets located on the pipe - Fig. 13.<br />

Fig. 13<br />

STEP 7.<br />

Attach the lower hot alloy intercooler pipe [B-2] to the upper hot alloy intercooler pipe [B-5] utilizing the silicone<br />

joiner [C-3] and hose clamps [D-3] as per Fig. 14. Following this, attach the lower hot pipe to the Fenix Pro <strong>Series</strong><br />

intercooler utilizing the joiner [C-3] and hose clamps [D-3] - Fig. 15.<br />

Fig. 14 Fig. 15<br />

STEP 8.<br />

Install the upper hot alloy intercooler pipe [B-1] located on the passenger side - Fig. 16, utilizing the OEM rubber<br />

turbo outlet and clamp - Fig. 12.<br />

Fig. 16 Fig. 17<br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS


INSTALLATION<br />

Following this, ensure the upper hot pipe is secured to the OEM mounting position and the BOV is<br />

reconnected to the OEM return pipe - Fig. 18.<br />

Fig. 18<br />

STEP 9.<br />

Attach the lower hot alloy intercooler pipe [B-3] to the upper hot alloy intercooler pipe [B-1] utilizing the silicone<br />

joiner [C-3] and hose clamps [D-3] as per Fig. 14. Following this, attach the lower hot pipe to the Fenix Pro <strong>Series</strong><br />

intercooler utilizing the joiner [C-3] and hose clamps [D-3] - Fig. 15.<br />

Fig. 19 Fig. 20<br />

STEP 10.<br />

Re-connect the battery. Prior to driving, we recommend you start the vehicle and ensure there are no leaks<br />

from the intercooler system. Once the system has been tested for leaks, re-install the factory bash plate.<br />

Fig. 21 Fig. 22<br />

We highly recommend that a boost gauge is installed when making any modifications to a turbo vehicle. An unchecked increase<br />

in boost pressure can result in boost-spiking & engine damage.<br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS


CONGRATULATIONS!<br />

YOU HAVE SUCCESSFULLY INSTALLED THE<br />

FENIX PRO SERIES INTERCOOLER KIT.<br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS


NOTES<br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS


#FENIXRADIATORS<br />

FENIXCOOLING.CO.NZ<br />

[NZ] 0800 757 333<br />

@FENIXRADIATORS

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