Manual Automotive: How to Instal AFCO Heat Exchanger On S197 Saleen

This thread will require several posts to complete so please be patient. About 4 months ago I decided to upgrade the Saleen S/C heat exchanger with one that was larger and more efficient. I read every thread on every forum I could find and talked to every manufacturer that was on my short list of vendors (Fluidyne, Gords, Afco, Saleen & Steeda). After carefully evaluating my needs for a daily driver and what each manufacturers product had to offer I chose to install the Afco GT 500 Pro-Series Dual Pass Heat Exchanger. Now for those of you that disagree with that choice you are entitled to your opinion but let me mention some facts that are indisputable:

• The Afco heat exchanger is a dual pass design heat exchanger rather than a single pass design

• The Saleen Series VI heat exchanger core measures 5" x 24.5" x 2" = 122.5 sq" of frontal surface area and 245 sq" total core area

• The Afco heat exchanger core measures 9" x 22.5" x 2.5" = 202.5 sq" of frontal surface area and 506.25 sq" of total core area

• The frontal surface area of the Afco unit is 165% larger than the Saleen heat exchanger

• The total core area of the Afco heat exchanger is 206% larger than the Saleen heat exchanger

• The Saleen heat exchanger tanks measure 5" x 2" x 2" = 20 sq" and holds approx 11 oz. of fluid

• The Afco heat exchanger tanks measure 9" x 4" x 2.5" = 90 sq" and holds approx 50 oz. of fluid

• The Afco heat exchanger tanks hold 39 oz. (450%) more fluid than the Saleen heat exchanger

• The fluid inlet connection on the Afco heat exchanger is on the same side as the Saleen heat exchanger but is pointed 180* from the direction it needs to point for a direct bolt in installation

• The fluid outlet fitting on the Afco heat exchanger is on the opposite end of the heat exchanger when compared to the Saleen heat exchanger

• The mounting of the Afco heat exchanger is identical to the Saleen heat exchanger. The Afco heat exchanger mounts on the back side of the front bumper and uses the 4 inner mounting bolts with vibration isolators and locknuts

• Lastly I picked this Afco heat exchanger up for $359.99 from D'Agostino Racing and the unit arrived UPS the very next day

I will not go into R&I of the front fascia as anyone that is considering this mod is more than capable of performing that task. Same holds true for removal of the Saleen heat exchanger.

Once the front fascia and Saleen heat exchanger was removed, the Afco unit was mounted to the backside of the front bumper on (4) longer bolts, with vibration isolators, spacers and locknuts. Be warned even though this unit is only .5" thicker than the Saleen heat exchanger, it is a very tight fit due to the inlet fitting sticking out of the rear of the heat exchanger. That fitting almost touches the A/C condenser. But with a little tweaking of the Afco heat exchanger mounting brackets, it will fit without touching the A/C condenser. The next issue is the P/S cooler. The brackets must be tweaked so the P/S cooler tubes are vertical and much closer to the A/C condenser than before. However, this can be accomplished without the P/S cooler touching either the heat exchanger or the A/C ondenser. Next is the coolant inlet fitting. It is on the correct end of the heat exchanger but the nipple points in the exact wrong direction. Not a big deal. (2) 3/4" 90* short hose elbows, a 3/4" barbed nipple and some clamps solve that problem and get the inlet hose pointed directly at the intercooler pump. Next is the heat exchanger coolant outlet fitting. It is on the wrong end of the heat exchanger. No problem. (2) more 3/4" 90* short hose elbows, a couple of 3/4" barbed nipples, some clamps, and a piece of 3/4" hose can be used to route the outlet hose to the opposite end of the heat exchanger and it easily connects to the original Saleen heat exchanger outlet hose. The following pictures are in no specific order.

I recommend if you going to do this job to get a helper to prevent damaging the heat exchanger or A/C condenser. I did this job entirely by myself which made the job take a little longer. Total time spent 5 hours.