Fitting an AVO Stage II Intercooler

[Antho]

Hi all,
Here is my guide to installing an AVO Stage II Intercooler to a VL.



Step 1:
Remove your standard crossover pipe taking note of the hoses/lines attached to it.

Step 2:
Remove your front bar with the reo still attached, as well as all moulding strips.

Step 3:
Attach the brackets to the top of the cooler and dummy fit the cooler to the car.

Once you are satisfied where the cooler is going to sit and when it is sitting properly mark the holes in the brackets and drill them out.

*Note: The cooler should be mounted slightly to the left of centre as per the picture.

Attach the cooler to the car



Step 4:
Dummy fit the front bar to your car and mark out where you will need to cut into the reo to clear the cooler.

Cut out the reo as per the picture below.



Step 5:
Dummy fit the piping to the top inlet and suitably mark where it will pass through the inner gaurd.

Cut a neat hole in the inner gaurd, making sure you smooth out and properly treat the edges so they dont rust.

Fit the piping to the bottom inlet and connect it to the turbo outlet.





Step 6:
Attach the rest of the piping between the bottom cooler oulet and the throttle body. No modification is necessary in this step, but make sure the piping clears the distributor cap and is tight so it won't move to much and hit things like the radiator cap.



Step 7:
Attach all the hoses and lines to the back of the crossover pipe in a similar fashion to how they were attached to the standard crossover pipe.



Step 8:
Cut 2 small holes / provisions in the bottom lip of your front bar as to clear the bottom cooler tank. See the picture below.



Step 9:
Double check all clamps and lines are tight and fit the front bar back up.



*Note: I do not take any responsibility for any actions taken while installing this setup. It is to be used as a guide only.

Antho...

[Boat captain]

Great set of instructions Antho. very helpful. Just one thing to point out about the mounting of the cooler that might help. if you can mount the cooler as far to passenger side as the brackets will allow you this will help when you go to fit the upper cooler pipe as the s bend is very shallow.

thanks heaps Antho much appreciated.

[mistake]

when i change an avo cooler stage2 to a bigger cooler etc etc whats needed?

[SII_Turbo]

i got one of them in my shed...ugly cooler!

[mistake]

but legal yes?

[SII_Turbo]

all coolers are legal though? isnt it only if its protruding?

[SII_Turbo]

which would then be in contradiction to ur legality claim as on the pic the cooler clearly protrudes past the bottom of the bar...please explain thnx mate!

[PROGMH]

Its legal where it is. Vicroads just say that nothing on the front of the car can have sharp edges. It doesnt.

[SII_Turbo]

LOL..just saw this..jeez i was a wanker when i posted that! the car looks mint and so does the cooler! good job and nice tech article!

[matsvlt]

good post mates helps allot

[ished]

haha wicked Antho!
Wish this was around when we bungled our way though this in 99 ...

[vl-blt1]

thanks for the article, it will help me fit my newly aquired avo stage 2 fmic.
bought it complete, s/h for $325 delivered. waiting for it to arive, but looks in top nic from the pics of it. seems that the price varies drastically on these too, seen one go without pipes for $100, and seen em go complete for more, checked the AVO site and theyr'e still $1599 retail, wow.

[FORZA]

can this be used 2 install a regular 600x300x70 cooler aswell?

never mind found another guide

[jackpot77]

great article should help many people. saw a vlct today with one of these cooler looks ugly but very effective from what i have read.

[kims88VLT]

What are people's thoughts on these cooler kits now days?? I am looking for one, currently running a no holes cooler kit with 600 x 300 x 75 cooler. Will it perform any differently? Pro's... Con's... General opinions
cheers, Kim