There is a slight difference between an 87-88 and 89-92 intercoolers. These instructions were originally for 87-88 models, but as you can see from the pictures, there is only a slight difference. You can see from the picture how they differ and what else you will need for 89+ models.
First you need to cut two sections of straight PVC, one 15" and one 10.25". The 15" piece glues into the 45 with a coupling and then the 10.25" piece goes into the flared out end of the 45. Put a 1/2" section of the exhaust tubing into the end of the 15" piece where it connects to the stock 45 rubber.
Now, cut a piece of the exhaust tubing about 1/2" wide off. Insert the piece into the ends of the pieces like in the picture. You may need to heat the PVC in order to get the band of exhaust tubing to go in. The piece of exhaust tubing keep the PVC from shrinking under heat and clamp pressure. These are the only trouble spots in a PVC system but this is a complete cure. You may note that I put rings around the PVC. This is simply to help keep the silicone from slipping off.
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You can also use the metal inserts in the stock plastic pieces.
Put the pieces together on the car without glue with the pieces of the stock rubber bends and mark everything so that you will know how they fit together.
Now disassemble pieces from car and put them back together again with all your marks lined up together and glue it. Remember to use the Purple primer. The glue joints will not hold without it.
87-88 Models Upper Section
89-92 Models Upper Section
Now paint the pipes with the color of your choice and clamp the stock 90 rubber on the IC side and the stock 45 rubber on the 3000 pipe side as in the pictures above.
Run the IC end of the new pipe down through the old airbox snorkel hole and attach the rubber 90 on to the intercooler tighten the clamps. Then attach the 45 rubber on to 3000 pipe and clamp it. Put the K&N back on and make sure everything is secure and all the things you disconnected are put back.
Get in and test the car and see how it works!
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