Here is a brief description of how I did it. This is NOT an instruction on how to do it, so if you break your Hilux or make a big hole in your hand - don't come blame me
OK - first up you need a Hilux KZTE - looks something like this:
Next up you are going to need the Cirrus intercooler - looks like so when you unpack the box:
Now in the box you'll also find a piece of paper that they call "Instructions" - these give you some pretty good pointers.
You will start off by removing the front bumper and grille) (This is kind of hard to do if you have a bullbar that is not removed yet
). Be patient when removing the grille otherwise you're going to break clips and things. Next up you must start sizing the intercooler up and how you are going to fit it. While I was trying to fasten the cooler with the rubber mountings that come with the kit, they broke - not very tough things. So I made my own plan using some suspension rubbers I had lying around in the garage.
Remove the standard boost pipe between the turbo and the throttle, also remove the 4 bolts from the throttle that hold the boost pipe in place.Remember to unbolt the boost sensor from the pipe as well. Take the first boost pipe from the kit and fasten it to the turbo's outlet.
Now here comes a part you won't enjoy - you have to make a hole on either side of the intercooler for the boost pipes to go through to the engine bay. Now in the instructions they suggest using a 76mm holesaw and make two holes and tadaaa... Ja whatever. A Hilux will not be mutilated that easily. You will have to use a jigsaw or the likes. I used a jigsaw to make these holes. After making them just touch up the bare metal with some paint to prevent corrosion before placing the rubber shielding on it. Feed the second boost pipe through and connect it to the intercooler. Use one of the supplied connectors to join it to pipe 1 - you may need to cut it a bit shorter. Feed pipe no 3 through the hole on the passenger side of the cooler and fasten it to the cooler with a hose clamp.
Use a small bit of silicon sealant and apply it to both sides of the spacer that goes onto the throttle. Place the metal boost pipe onto this and fasten with the supplied bolts. Fasten the fourth boost pipe onto the metal boost pipe, and connect it to the third boost pipe using a connector.
(Sorry for the lack of pictures up to here - was too busy looking for my sense of humour to take pictures at this stage
)It should now look more or less like this:
Like I said earlier - this kit is actually designed for the facelift model. I had to modify my front bumper to make it all fit (Not particularly happy about having to do so....)
This is how mine looks now:
After re-painting the bullbar and re-fitting the spotlights
In terms of results, I am rather impressed. Even though I have not fiited a chip yet, I can feel a very real difference. I used to feel the boost started at around 2100rpm and lasted to about 2800rpm. Now it starts boosting at around 1900rpm and boosts past 3000rpm. Response is much better and it feels like I have to give less throttle input in every day driving.
