Upgrading your Mitsubishi Lancer Evolution IX with a front mount intercooler (FMIC) is one of the most effective modifications to improve the car’s performance and reliability, particularly for enthusiasts seeking to maximize power output from the turbocharged 4G63 engine. The FMIC replaces the factory top-mount intercooler with a larger, more efficient unit mounted at the front of the car, directly behind the grille. This setup provides a greater surface area for cooling intake air, reducing temperatures more effectively and increasing the density of the air entering the engine. Cooler, denser air enables better combustion, resulting in increased horsepower, improved throttle response, and reduced risk of heat soak during spirited driving or track use.

Benefits of Installing a Front Mount Intercooler on the Evo IX

The factory intercooler on the Evo IX is a top-mount design, positioned on top of the engine. While compact and effective for stock power levels, it has limitations under high boost or extended aggressive driving. Installing a front mount intercooler offers several key advantages:

  • Improved Cooling Efficiency: The FMIC is positioned to receive direct airflow from the front grille, allowing it to dissipate heat more quickly and maintain lower intake air temperatures.
  • Increased Boost Potential: Cooler intake air allows for safer increases in boost pressure without risking detonation or engine damage.
  • Reduced Heat Soak: On the track or during performance driving, the stock intercooler can become heat-soaked, reducing its effectiveness. The FMIC reduces this risk by being exposed to constant fresh air.
  • Enhanced Turbocharger Efficiency: Lower intake temperatures improve the turbo’s efficiency, allowing it to spool faster and deliver more consistent power.
  • Supporting Other Modifications: If you plan to upgrade turbochargers, fuel systems, or engine internals, an FMIC is often essential to keep intake temperatures in check.

Tools and Materials Needed

Before beginning the installation process, ensure you have all the necessary tools and parts on hand. Using the correct equipment will help you complete the job safely and efficiently.

  • Front Mount Intercooler Kit: Choose a kit specifically designed for the Mitsubishi Lancer Evolution IX to ensure proper fitment. The kit usually includes the intercooler core, piping, silicone couplers, hose clamps, mounting brackets, and hardware.
  • Socket Wrench Set: A comprehensive set with metric sockets, extensions, and ratchets will be needed to remove bolts and fasteners.
  • Screwdrivers: Both Phillips and flathead screwdrivers will be useful for removing screws and clips.
  • Hose Clamps and Silicone Couplers: These secure the intercooler piping and prevent boost leaks.
  • Jack and Jack Stands: Safely raise and support the vehicle to access the underside and front components.
  • Safety Equipment: Gloves and goggles protect your hands and eyes during disassembly and installation.
  • Zip Ties and Mounting Brackets: Often included in the kit but useful for securing wiring or hoses away from moving parts.
  • Trim Removal Tools: Optional but helpful for removing plastic clips and trim pieces without damage.
  • Torque Wrench: Ensures bolts are tightened to manufacturer specifications, preventing overtightening or loosening.
  • Penetrating Oil: Useful if bolts or clips are corroded or stuck.

Preparation and Safety Precautions

Before starting the installation, it’s important to prepare your workspace and take safety precautions to avoid injury or vehicle damage:

  • Work in a Well-Ventilated Area: If you need to run the engine during testing, ensure the area is open to avoid carbon monoxide buildup.
  • Wear Protective Gear: Gloves will protect your hands from sharp edges and hot surfaces, and safety goggles prevent debris from entering your eyes.
  • Disconnect the Battery: To prevent any electrical shorts or accidental airbag deployment, disconnect the negative terminal of the battery.
  • Check the Vehicle’s Condition: Ensure the car is cool before starting to avoid burns from hot engine components.
  • Gather All Tools and Parts: Lay out everything you need within reach to avoid interruptions during the procedure.

Detailed Installation Steps

Installing a front mount intercooler on the Evo IX involves several stages: removing the stock components, fitting the new intercooler, and ensuring all connections are secure. Follow these detailed instructions carefully:

1. Vehicle Preparation

Park your Evo IX on a flat surface, ensuring the parking brake is engaged. Use a jack to raise the front of the car and secure it with jack stands for safe access to the underside and front bumper area. Lay protective mats or cardboard beneath the car to keep the workspace clean.

2. Remove the Front Bumper Cover

Removing the front bumper is necessary to access the factory intercooler and piping. Start by opening the hood and removing any plastic clips or screws securing the bumper to the fenders and radiator support. Typical fasteners include:

  • Plastic push clips along the wheel wells
  • Phillips screws near the headlights and under the bumper lip
  • Bolts along the bottom edge of the bumper

Use a trim removal tool or flathead screwdriver to gently pry clips loose without breaking them. Carefully pull the bumper straight forward to disengage it from retaining tabs, then set it aside on a clean, soft surface to prevent scratches.

3. Disconnect and Remove the Stock Intercooler

The stock top-mount intercooler is located on top of the engine, connected via piping to the turbocharger and throttle body. To remove it:

  • Loosen and remove clamps securing the intercooler piping.
  • Disconnect any sensors or vacuum lines attached to the intercooler.
  • Unbolt the intercooler mounting brackets.
  • Carefully lift the intercooler out of the engine bay.

Inspect the piping and hoses for any damage or wear that may need replacement during installation.

4. Prepare the Front Mount Intercooler and Piping

Unpack the FMIC kit and verify all components are present. Lay out the intercooler core, piping, silicone couplers, clamps, and brackets. It’s beneficial to pre-fit the piping and couplers to familiarize yourself with the routing and connections. Some kits may require minor trimming or adjustments to fit perfectly.

Clean all mating surfaces and piping ends to ensure a tight seal. If desired, apply a small amount of lubricant (such as soapy water) inside the silicone couplers to aid installation.

5. Install the Front Mount Intercooler Core

Position the intercooler core behind the front grille, in front of the radiator. Align it carefully to maximize airflow and avoid contact with any moving parts or wiring. Use the provided mounting brackets and hardware to secure the intercooler firmly to the chassis or radiator support.

Ensure the intercooler is level and centered, with adequate clearance from the radiator and bumper to prevent vibration or damage. Tighten all bolts to the recommended torque specifications.

6. Connect the New Intercooler Piping

Attach the intercooler piping to the turbo outlet and throttle body inlet using the silicone couplers and hose clamps provided. Follow the routing designed by the kit manufacturer to avoid sharp bends or kinks, which can restrict airflow and cause boost leaks.

Tighten all hose clamps securely, but avoid overtightening, which can damage the silicone couplers. Double-check that all piping connections are flush and sealed.

Use zip ties or mounting brackets to secure the piping away from heat sources, suspension components, or any moving parts to prevent wear or damage while driving.

7. Reinstall the Front Bumper

Carefully reinstall the front bumper cover by aligning it with the fender tabs and radiator support. Reattach all clips, screws, and bolts removed earlier. Ensure the bumper fits properly over the new intercooler and piping without rubbing or pinching.

Double-check that all fasteners are tight and the bumper sits flush with the body panels.

8. Final Inspection and Testing

Before lowering the vehicle, visually inspect all intercooler piping and connections for any loose clamps or potential interference. Reconnect the battery negative terminal.

Start the engine and let it idle. Listen carefully for any hissing sounds indicating boost leaks. You can also use a boost leak tester or spray soapy water around hose connections to check for bubbles.

Once confirmed that no leaks exist, take the car for a cautious test drive, gradually increasing boost and monitoring engine behavior. Watch for any check engine lights or unusual noises.

After the test drive, perform a final check of all clamps and mounting points to ensure nothing has loosened during operation.

Additional Tips and Considerations

  • Intercooler Core Size: Selecting the right size intercooler depends on your power goals. Larger cores provide better cooling but may cause increased turbo lag due to volume. Consult with performance tuners or intercooler manufacturers to find the optimal balance.
  • Professional Tuning: After installing an FMIC, it’s advisable to have your Evo IX professionally tuned. The cooler air charge and altered airflow dynamics may require adjustments to fuel maps and boost control to maximize performance and prevent engine damage.
  • Supporting Upgrades: For best results, consider upgrading supporting components such as an aftermarket intake, larger turbocharger, high-flow fuel injectors, and performance exhaust to complement the FMIC.
  • Maintenance: Periodically inspect the intercooler and piping for damage, leaks, or debris buildup. Clean the intercooler fins carefully to maintain optimal airflow.
  • Installation Assistance: While the installation can be performed by experienced DIYers, enlisting the help of a friend or professional mechanic can make the process smoother and safer.

Conclusion

Installing a front mount intercooler on your Mitsubishi Lancer Evolution IX is a transformative upgrade that enhances the efficiency of your turbocharging system, leading to improved power delivery, reduced intake air temperatures, and greater engine reliability. By carefully following the detailed installation steps outlined above, using the proper tools, and taking necessary safety precautions, you can successfully complete this modification and enjoy the benefits of a cooler, more powerful Evo IX. Whether you are a weekend racer or a dedicated enthusiast, the FMIC upgrade is a cornerstone for unlocking the full potential of Mitsubishi’s legendary turbocharged platform.