The last time we tested this 240SX (dyno and track) we felt a loss of power after a few passes. The culprit was the side-mount intercooler tucked behind the bumper on the driver's side. We drilled holes to direct more air to the tiny aluminum box, but when the turbo is forcing hot exhaust gases through it, there's only so much it can do-even just touching it, you'd burn your hand. A front-mount intercooler upgrade was a must to get the SR-powered 240 running more efficiently. Since this is a budget build-up we sourced out the new GReddy Spec M front-mount intercooler kit. The bar-and plate design makes the kit more cost effective, but the results are still substantial.
1. Here's a look at the GReddy Spec M intercooler kit. It comes with a huge bar-and-plate-style intercooler, the majority of the piping, silicone boots, brackets and pretty much everything you need for the install. | 
2. Since you have to drill a hole through the battery tray, you need to either relocate the stock battery to the back or use a smaller unit like this one we picked up from Phase 2 Motortrend. |
3. Use a 10mm wrench to disconnect the terminals of your battery. Then take the battery out. | 
4. Use a flathead screwdriver to loosen the hose clamps on the throttle body side of the engine. |
5. With a pair of pliers, take off the breather hose on the plastic intercooler pipe. Pop everything on the throttle body side loose. | 
6. On the turbo side, use a flathead screwdriver or 8mm socket to loosen the clamps from the piping to the intercooler. |
7. Jack the car up and put it on jack stands to remove the wheels. | 
8. Using a Phillips head screwdriver, loosen the screws that hold in the fender lining. Pull the plastic lining to the side to access the stock side-mount intercooler. |
9. With a 12mm socket, loosen all the bolts that hold the stock side-mount intercooler to its brackets. | 
10. Take the side-mount intercooler out. Are your hands cut up yet? Shoulda worn stylish purple gloves like we did. |
11. We think it's safe to say that the GReddy Spec M front-mount intercooler is going to keep temperatures down much more efficiently than the stock side-mount | 
12. Back to the fun stuff. There are five 10mm nuts on each side of the bumper holding it to the fenders. Use a ratchet with a really long extension to reach these - We bet you'll yell out profanities while you're doing this, just like we did. |
13. Go to the engine bay and loosen the 10mm bolts that hold the bumper to the radiator and headlight supports. | 
14. Along the bottom of the radiator support, use a Phillips head screwdriver and prying tool to pop out these annoying plastic clips from the bumper. |
15. You're still not done yet! Use a 10mm socket to loosen the four 10mm bolts in the middle of the bumper that hold it to the metal reinforcement. | |