Next i cut the washer bottle front section where it bolts to the body.
This was needed as it closes the gap of another plastic panel and also provides a mounting point for the fender liner

Plastic panel in place, Clears the filler neck also you can see how the HE is away from the liner out line

My hoses have been made for the front main HE and should pick them up next week

For those that don't remember well it was nearly 3 years ago :)
I had a jig made for a custom hose for the A/W inter cooler , well also the one for the vent on the engine. But since i changed the setup with the 2nd HE with fan and also a much bigger water pump i had the pipe modified to suit and the hose made.
Its actually 2 sections made as one which i will cut. It was cheaper this way as i get charged for only one.
Out of most of the things i have done this is on the top 5 of the list as it really makes the HE disappear and look OEM. Pipes hanging out and not angles to clear obstacles doesn't look clean IMO.

This is half of the pipe and test for fit. Looks OK

For those who dont know this is the front layout.

Need to get a tab bigger belt for the SC.
All the pulleys are custom. This is because the SC has a 6 PK belt which in turn made all the alternator side out of alignment, hence new idlers , alternator pulley even the A/C pulley. If you look in the past threads you will see how i made them all.
So its ready to rock and roll :)  But wont be in for a tune till December because of work commitments.

Installed the Johnson CM90 water pump for the A/W intercooler.
In a verticle position it clears the pop up light and also the entry hose at the bottom will also clear the Inner guard liner :)

Also room for the Ferrari compressor

custom hose is a great fit

Engine all ready to go in :)  Next picture of the engine will be when its in

Only issue was that the O2 sensor is too close for my liking to the axle bearing support so i will weld a new bung . This unfortunately caused me not to install the exhaust system. I can do it at home but on a hoist it would of been a sinch.
Oh well that was the only thing . Installation went flawlessly , everthing cleared. Adding the axles and new hubs was easy. Everything just glided in.
Here are some better shots
Engine ready to go in


While lowering the car to the engine i get in the boot and fed the engine harness into the opening of the boot , its so much easier this way

All clear about an inch in the lower section and 2 inches clear higher up
 

Beams N/A engine but all the engine threads are there for the Turbo drive train upgrade

New axles with CV upgrade and new complete hubs/carrier/bearings and shields in

New fuel filter in and all the necessary lines connected , coolant/clutch lines etc. Also upgraded the 2 shifter lines to a pair of new turbo ones to match the E153.
**** a brick there are many parts to change to go to the E153 Turbo gear box. Admittedly dear when new but its well over $6,000 just for those parts.
OK need a few days off and get back to it but will take a few weeks break for work commitments.

In place powder coated

So now back to putting all the connections to the engine. You can see I'm using the charcoal canister, don't know why there are those that delete it.
Also where the MAF normally resides it is very close to the coolant neck filler hence why i made the part to attach to the air box and the angled air line to the Idle control valve
  The WG and BOV totally out of sight


As you can see I'm using the OEM air box. I avoided the temptation to change it as l prefer the OEM look even if i have sacrificed some HP. The inter cooler is also totally out of sight and still have all the space b/w the engine and the car :)
 
Well thats about it for a couple of weeks as i have work commitments. I needed it at this stage as i have added the coolant and i can let it sit so as to burp out any air

So for those that are not familiar these are the 2 mandrel bent aluminum pipes that are of the A/W Intercooler system. There are another 2 aluminum sections under the frunk also with rubber hoses connecting them all in the system.

With the hoses there were the custom ones in the front but with the other ones i just looked for off the shelf hoses that would suit and cut the sections that i needed. This way the ID of the hose is kept uniform as they are shaped

Well its all hooked up and as i said man it is so hard to bleed the system so i resorted again to the system i used the first time.
I put a valve on my garden hose , disconnected the A/W pipe after the 2 HE . Connected lenghts of hose and turned on the water tap into one hose with the other going into the bucket. Simultaneously i turned on the A/W water pump. This removed all the air to the intercooler and to the front in 5 seconds.. Then i removed the garden hose and allowed the pump to suck water from the bucket.
Once i was happy i pinched the those 2 long hoses and reconnected the A/W lines.
Once stabilized i added a bottle of Wetter Water.
I HATE BLEEDING !!!!!!!!!!!!

I will say this Johnson M90 sure does pack a punch. When i squeeze the hose out of the pump you can feel the pressure