I am installing my Hahn Stage II kit and got around to the intercooler and piping. I ordered a side mount intercooler and the 2" silicone hose used to join the intercooler pipe from the turbo to the intercooler inlet (bottom of intercooler) does not fit on the intercooler. There is no possible way of getting it on. I was just wondering if anyone else had this problem. I am going to call Hahn tomorrow but in the meantime I have ordered a silicone reducer 2" to 2.25" to use instead. I've measured both the intercooler piping and the intercooler inlet also (Pipe is 2" the intercooler is +/- 2.25").

Thanks,
Kurt

I didn't use the HRC i/c pipes, but I think the pipe going from the turbo to the i/c inlet is 2.25", and the i/c going from the i/c outlet to the throttle body is 2.00" Did you get two 90 degree silicone elbows? I thought one is 2.0"" and the other 2.25" If you can't get it to fit, you might want to apply some engine oil to the inside of the silicone elbow firs.

If i remember right, someone correct me please if i'm wrong, that the 90 degree coupler is 2" at one end, then 2.25" at the other, then the pipe going from the elbow to the IC is 2.25", and the outlet of the IC is also 2.25", but then the pipe increases in size to 2.5" to the TB inlet...

you have the wrong sleeve then. mine fits fine. there are two different sleeves. one is 2" and other is either 2.25 or 2.5. the 2" is the one on the bottom so unless you have a smaller one then that, then it should work

Thank for the help guys. I have tried all that has been recommended. I tried the next size up sleeve (2.25) and it fits on the intercooler perfectly but not on the intercooler pipe (the sleeve is too big and would cause a leak when clamped). Anyways, if I used the 2.25", the 2" would not fit on the throttle body. Here is what I received in the kit and how I tried to connect it. I think Hahn may have sent the wrong piece. I can't be out of my mind :).

There are four silicone sleeves:

1 1/2" x 2" for the blow off valve
2" x 3" for the intercooler intake (bottom)
2 1/4" x 3" for the throttle body intake
2 1/2" x 3" for the compressor intake (air filter pipe)

There are two rubber elbows:

2" for the compressor discharge (pointing towards the drivers side)
2.25" for the upper intercooler out (pointing towards the engine)


I have tried putting some liquid soap on the 2" thermal flex hose (since oil is not good for silicone) and pressing it on. I am almost positive that I am using the right hose since it fits perfectly on the intercooler piping but not on the intercooler. Guess my best bet is to wait till the reducer hose (2" to 2.25") arrives Wednesday.

Thanks again,
Kurt

do you have the intercooler mounted correctly? it should mount on the drivers side just in this postion

Yes, that is the exact position I have the intercooler in. The side bracket is attached to where the horn was previously mounted and the rear bracket is mounted to a 5/16th hole that I drilled underneath the Powertrain(ECU)/fuesbox. The inlet on the bottom is pointing towards the turbo (passenger side) and the top port on the intercooler is under the fusebox through the 3" hole saw that I drilled.

I just got off of the phone with Hahn and they have re-engineered the intake fitting on the side mount intercooler. He is sending me a flex reducer (2" to 2.25") to fit on the intake of the intercooler. Apparently the lip on the intercooler used to be 2".

Just a note of caution to those who have recently ordered a kit in the past month that they may have to call Hahn and have them ship this reducer once they get to the intercooler part of the install. If you are planning to order, you may want to bring this up just to make sure you get the right part.