HKS Intercooler Kit 13001-AM007 Installation Manual

Important Information Before You Begin

This installation manual is intended for the HKS Intercooler Kit (13001-AM007) for the Mitsubishi Lancer Evolution X (CBA-CZ4A, 4B11 engine, 2007/10 onwards). This installation requires familiarity with automotive systems and basic service procedures. Always have a factory repair manual on hand for safety and reference.

Required Items:

• Power Steering Fluid (Mitsubishi ATF II)
• Paint (Body Color or Black) for touching up cut portions
• Standard automotive tools

Important Advice: For optimal performance, use with factory piping or the HKS Piping Kit (P/N 13002-AM003). Using non-HKS piping may result in fitment issues.

Necessary Modifications

Installation requires several modifications to factory parts. Ensure you have the necessary tools to cut, disassemble, and relocate components as detailed in the manual:

• Power steering cooler pipe: Modify pipe shape and bracket.
• AC condenser: Remove stopper/cut stopper and add gaps in the bracket.
• AC pipe: Modify pipe shape.
• Headlight support upper panel: Cut bracket.
• Reinforcement: Disassemble rivets, cut sections, and add gaps to the power steering pipe bracket and reinforcement.
• Front bumper air guide duct: Cut off protruding sections.
• Intercooler bracket (RH): Cut bracket.
• Front bumper air guide: Cut plastic.
• Headlight support cover: Remove ribbed section.

Removal of Factory Parts

1. Disconnect the negative terminal cable of the vehicle’s battery.
2. Remove the air cleaner duct (this part will be reused).
3. Remove the engine room under covers (front A, front B, and center).
4. Remove the headlight support cover, front bumper assembly, front bumper air guide center duct, and front bumper reinforcement.
5. Remove the intercooler pipe, hoses, and intercooler core assembly. Keep bolts and hose clamps for reuse.

Installation of Kit Parts

Relocating the Power Steering Cooler Pipe

Prepare a drainage tub for power steering fluid. Bend the cooler pipe to avoid contact with the front bumper assembly and AC condenser. Use the provided Power Steering Pipe Bracket to mount the pipe vertically.

Relocating the AC Condenser

Relocate the AC condenser approximately 5mm to the vehicle's left by cutting the right-side stoppers. Use tie wraps to secure the condenser in the newly created gaps.

Intercooler Core Assembly Installation

Install Intercooler Bracket No.2. Pre-tighten the lower bolt of the Intercooler Core Assembly to check for contact points. Bend the AC pipe (thin) towards the rear of the vehicle to prevent contact with the intercooler tank bottom. Caution: Do not apply excessive force near flanged sections of the pipe to prevent leaks.

Procedures After Installation

After installing the kit, you must bleed the power steering system:

1. Reconnect the negative battery terminal.
2. Jack up the front of the vehicle and support it on jack stands.
3. Disconnect the crank angle sensor.
4. Refill power steering fluid to the minimum level.
5. Crank the engine intermittently (15-20 seconds) and turn the steering wheel right and left until it locks (repeat 5-6 times).
6. Reconnect the crank angle sensor, start the engine, and let it idle.
7. Turn the steering wheel until the reservoir stops bubbling.
8. Verify fluid levels are stable and not cloudy.