Polaris XP Turbo/S Air to Air Intercooler Kit

Make sure the vehicle is cold. You can either remove the rear facia, exhaust and heat shields or remove the bed. For these instructions we removed the bed for photos. Both options work well.

Locate the plenum. Spray the plenum boots with brake cleaner. Remove the charge tube, unplug both map sensors, unplug the coils, remove the fuel line.

You may need to remove the plenum from the vehicle to remove the intercooler. Sometimes you can sneak the intercooler around the frame, but you may ruin the intercooler fins in the process. For these instructions we removed the plenum.

Pinch both coolant lines off, going to the intercooler. Remove the hoses from the intercooler. Plug the intercooler for less mess.

Remove the 13mm bolt on bottom of the plenum/transmission mount.

Remove the intake plenum V-band clamps on the runners, remove the plenum from vehicle.

With a 8mm socket, remove (10) screws holding the intercooler into the plenum. Remove the plenum and look for oil/coolant in the bottom of your plenum. Clean any debris that is found in the plenum, the OEM intercoolers are prone to leaking.

Install the supplied intercooler block off plate, re-use OEM hardware and bracket.

Reinstall the plenum into the vehicle. Reconnect everything except the charge tube.

This step is totally up to the customer. You can install the supplied 5/8” 90-degree hose barb and tie the coolant hoses together, if you think you may go back to the OEM intercooler at some point. Or you can remove all the soft/hard lines going up to the radiator and remove the radiator.

With the bed/body reinstalled, install the turbocharger to intercooler charge tube.

Move your map sensor over to the new charge tube. Aluminum plate is provided. Install the intercooler to throttle body charge tube.

Remove (4) cage bolts and nuts. Install the intercooler onto the cage and re-torque all (4) bolts.

Install the charge tubes to the intercooler. Use supplied T-bolt clamps.

Install a blow off valve or plug into the throttle body charge tube. Run the vacuum line up to the plenum hose barb.

Intercooler wire harness below.

Underneath the driver seat (rear passenger if 4 seater), mount the relay harness to the frame. Connect both positive and negative to the battery. Route the intercooler fan and water pump connector through the firewall.

Remove the water pump connector from the OEM harness and plug in the intercooler harness.

Key the vehicle on and make sure your intercooler fans turn on. Make sure the fans are pulling air through the intercooler, NOT pushing.