The problem with fitting the standard Newage STi intercooler to a Phase 1.5 Classic is that the dump valve flange protrudes too far and catches on the IACV. After much deliberation i decided the best way to get around this problem would be to patch in an original Phase 1.5 dump valve port.

I picked up an MY98 intercooler on eBay and cut a section from it before stripping the paint off. I then set about cutting away enough of the Newage intercooler before having the patch welded in. Brackets were fabricated and Samco hoses chopped until it all went together snugly. You can read a full write up for fitting the intercooler here.

While the car was in pieces i used the opportunity to slide some Insulating Inlet Manifold Spacers under the manifold. Together with the intercooler i've seen a marked reduction in inlet temperatures. Not only this but temperatures are far more stable than before with the smaller intercooler.

Unfortunately at the beginning of the month the Cavaliers prized C20LET engine started to tap so i've decided to take it off the road for a while. This paved the way for a new run-around. I spotted the 205 on eBay but missed out in the auction. A couple of weeks later the seller got in touch saying the deal had fallen through and the car was still available. Two days later i am the proud owner of a 1991 1.9 litre 205 GTi. :-)