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Focus ST Front-mount intercooler

Why do it

Tools you'll need

• Jack and jack stands
• 3/8" ratchet and 6" extension
• T20 and T30 Torx bits
• 1/4" ratchet and 7mm socket
• 10mm and 8mm stubby wrenches
• Flathead screwdriver or pick
• Flashlight

Parts to buy

• Vortech intercooler upgrade 8N310-020 Direct swap with no cutting, black finish, includes sleeves and hardware. The same intercooler as our video.Fits 2013–2018

Double-check fitment before buying.

Steps

1. Lift the car

   • Raise the front and support it on jack stands, or use a lift. Have T20 and T30 Torx bits ready; most of the front end uses them.
   ▶ Watch this step (1:00–1:28)

2. Remove the top of the bumper

   • Remove the four push clips along the top: pull the centers out, then the clips.
   • Unhook the hood release cable from the latch (push the latch over and the cable slides out the top), pop off its clip, and remove the two Torx screws at each end.
   ▶ Watch this step (1:26–2:16)

3. Remove the under-tray

   • Underneath, remove the air deflector and the belly pan. Both are held on by Torx screws.
   ▶ Watch this step (2:01–2:37)

4. Remove the lower and wheel well screws

   • Remove the seven screws holding the lower bumper to the body.
   • In each wheel well there are three more: one at the bottom, one hidden behind the bumper, and one just inside. Then release the two small clips on each side.
   ▶ Watch this step (2:37–3:11)

5. Pull the bumper off

   • Start at a wheel well and pull the bumper outward. Be gentle with the tabs under the headlights; slip a small screwdriver in and lift them free.
   • Unplug the fog lights before you set the bumper down on a towel.
   ▶ Watch this step (3:11–4:00)

6. Remove the grille shutters

   • Remove the T30 screws holding the shroud and slide it off its lower clips.
   • Unplug the shutter connector on the side of the radiator support, unclip the upper grille, then lift the shutters out one corner at a time and rest them on the intercooler.
   ▶ Watch this step (3:58–5:25)

7. Remove the stock intercooler

   • Remove the two small 8mm bolts under the intercooler (a stubby wrench helps).
   • Pull the pipes off both sides. They're tight, so wiggle them back and forth. Unplug the MAP sensor and lift the intercooler out.
   ▶ Watch this step (5:25–6:20)

8. Move the MAP sensor over

   • Remove the MAP sensor from the old intercooler and fit it to the Vortech using the factory hardware.
   ▶ Watch this step (6:15–6:36)

9. Fit the new intercooler

   • Plug the MAP sensor in, then lift the intercooler into place so it tucks up under the factory bracket.
   • Connect the pipes on both sides and tighten the clamps firmly. Bolt the bottom to the radiator support with the supplied hardware (nut on top, bolt from below).

   Tip: Check every clamp twice. A loose pipe here is a boost leak, and the car will feel slow.

   ▶ Watch this step (6:36–7:24)

10. Refit everything

    • If you're leaving the shutters out, zip-tie their harness out of the way. Otherwise refit them.
    • Refit the grille, shroud, bumper, fog light plugs, screws, clips and hood cable in reverse order. Test the hood release before closing the hood.
    ▶ Watch this step (7:24–9:20)

How to know it worked

• No boost leaks (no whooshing sound, normal power).
• No check-engine light.
• Hood opens and closes normally.

Follow your part's instructions and your service manual's torque specs.