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Discussion Starter #1 (Edited)
I'll start with the update of my experience letting COBB know the MAP sensor bolt was missing.

I contacted COBB immediately after discovering the MAP sensor bolt is not included in the kit.
I double checked the part list and the photo: 793500-BK_main.jpg
• COBB Black or Silver Front Mount Intercooler Core
• (8) Anti-Vibration Washers
• (4) M6x30mm Bolts
• (16) M6x18mm washers
• (4) M6x20mm Washers
• (4) M6 Lock Nuts
• 2.5" - 2.75" Silicon Coupler
• 90° Silicon Coupler
• (2) Stainless #40 clamps
• (2) Stainless #48 clamps
• COBB Stencil

Well no M6 x 12mm bolt listed.
But when you get to step 19:
“Now, after double checking that it's in good shape, you can reinstall the MAP sensor onto the new COBB core using the provided M6x12mm bolt and tightening it down with a 10mm wrench.”
It was already after 4 pm on a Friday so I knew they wouldn't get back to me. So I had to figure it out myself or put it back together and wait for their response. I spent at least an hour testing every spare screw and bolt I had in my garage. Now off to Home-depot. I took the intercooler with me just in case the bolt indicated on the install instructions (M6x12mm) didn't fit. I still had to go in and out of the store several times to find the correct bolt, as I wasn't about to drag an intercooler around Home-depot. I found the correct bolt. It was a 7mm x 1mm x 12mm bolt. I got home and installed the intercooler.
You may ask yourself “WTF are these couplers for?” or “Why does the kit include a 90-degree silicone coupler and a 2.5" - 2.75" silicon coupler?” Well, they are only useful if you purchased the hard-pipe kit. Yes, instead of including two sets of couplers with the hard-pipe kit, one for the stock intercooler and one for the after-market intercooler. COBB opted to include the couplers for the hard-pipe kit with the intercooler. Interesting choice…
I emailed COBB customer service again to let them know I found the correct bolt for the MAP sensor. I informed them the bolt listed in the installation instructions for the MAP sensor incorrectly as a M6 and the bolt I found to work was a M7 or 7mm x 1mm x 12mm bolt. I asked them to follow-up with me and assure me they would send out the fix to anyone who had ordered the intercooler.

At the end of the Monday I received a response from COBB. They apologized for the issue and said they would send me replacement bolts (2 for whatever reason) and a shirt.
I let them know I appreciated the response and I just wanted to make sure no one else had to deal with the issue and inconvenience I did.
This week the “fix” and the COBB shirt arrived. As soon as I opened the box I could see they ignored what I told them in my email. I was specific when I told them the M6 did not work and I had tried several different bolts before discovering the M7 worked. So, I pulled the front end off… again, because maybe I’m crazy. I test their bolt and they fall right in the hole (I made a video
, sound effects provided by my daughter). I sent another email to COBB with the video of their bolts and offered to return the intercooler so they could test it for themselves.
They said they would investigate it and I didn’t need to return it as the video was enough to investigate the issue.

SMH…

First impression: Dang this thing is heavy, around 40 lbs heavy.
Worst parts of the install (besides the above): Fitting the cold-side pipe over the intercooler connection.
Lasting thought: These freaking bolts are going to loosen and my intercooler will be crooked.

The intercooler is heavy. So heavy in fact it partially broke through COBBs packaging. The kit was well packed and arrived undamaged, even though the box was damaged. IMG_4209.JPG IMG_4214.JPG IMG_4212.JPG
COBBs install instructions cover the install well. https://cobbtuning.atlassian.net/wiki/spaces/PRS/pages/484868105/793500+-+Focus+RS+Front+Mount+Intercooler
I’ll add a few tips.
Make sure you remove the headlight assemblies. With them removed you will be able to release the bumper and access the back side of the fender to bumper fasteners. The plastic push rivet connecting the fender liner to the bumper is probably the most difficult fastener to remove. When removing the headlights wiggle them, lift the rear slightly and slide them forward.
Don’t close the hood if you have disconnected the hood release. It’ll be difficult to reopen, but not impossible.
The black plastic bumper support must be reinstalled. You can reinstall the soft rubber/plastic air diverters, but not the hard-plastic ones.
I removed the stock clamps from the stock hoses. This made it easier to get the stock hoses over the larger intercooler nozzles. I used two of the hose clamps included in the kit instead of the stock clamps.
Make sure you line it up and double check all of the bolts are tight before you move put the bumper back on the car.
Use an open-ended wrench to hold the rear bolt when tightening the upper bolts. If you use a socket or a closed-ended wrench it may bind and make it difficult to remove without loosening the bolt. IMG_4499.JPG IMG_4498.JPG
IMG_4500.JPG
You should be able to have the top of the intercooler flush with the metal bumper. This will assist in making sure the intercooler is straight.
When refastening the bumper, ensure you push the bumper in against the core support to achieve a good fit.
Don’t forget to plug your fog lights back in before the bumper is reinstalled.

The review:
I’m disappointed in the overall execution of the intercooler. Both CPE and Mountune utilized the stock mounting points which help eliminate the alignment issues. I almost didn’t purchase the intercooler because I thought it involved drilling into the metal bumper. However, no drilling is required to install the intercooler. I think the hardware package is lacking quality and is a bit annoying to assemble behind a metal bumper.
The intercooler seems to be doing what it was built to do. I’ve seen near ambient temps on just about every log. I’ll post some ambient vs intake temps once I have some good data. Throttle response feels close to stock, if not unchanged.
I’d probably be happier with the purchase if the MAP sensor bolt issue didn’t happen. I can’t help but think I probably should have used some Loctite on the bolts. Hopefully I don’t have any issues with the intercooler moving around.

IMG_4492.JPG

IMG_4505.JPG
 

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Call Cobb and ask for Billy. He’ll get you sorted out.
 

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Discussion Starter #4
Pics of 9/32” bolt?
I used an M7x1mmx12mm bolt. I didn’t try the 9/32”. I tried M6, M7, and M8.

It’s installed, so I won’t be testing the 9/32 theory. I found 9/32 on a conversion chart as the next size larger then M7.
 

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Inch fasteners go from 1/4” to 5/16”, there is no 9/32” in standard inch threads.

9/32 BSF does exist but you are unlikely to encounter it.

#3 BA has a major diameter of .282” but Cobb Tuning is unlikely to be using BA fasteners.
 

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Are there still missing parts from COBB on new orders? Am keen on the package but as I’m located overseas, wouldn’t want to deal with hassle of additional shipping for missing parts


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Discussion Starter #7
Are there still missing parts from COBB on new orders? Am keen on the package but as I’m located overseas, wouldn’t want to deal with hassle of additional shipping for missing parts


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Hopefully they will get it sorted out. As of now they haven't fixed the issue. They ignored me when I let them know the intercooler was tapped for the wrong bolt.
It should be an easy fix, but they need to step up and fix it.
 

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Discussion Starter #8
The blue section can be reinstalled, but it will contact the intercooler. The red section is a bumper support and must be reinstalled.
 

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Discussion Starter #10
All what did Cobb do to correct your issue?
Sent me the bolt I already had installed...

Overall pretty poor response to a customer informing them of a product issue.

Reading is hard...
 

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Discussion Starter #12 (Edited)
The bright side is no one else should have to deal with the issue.

Stay tuned as I will be doing some ambient vs charge air temp comparisons.
 

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The blue section can be reinstalled, but it will contact the intercooler. The red section is a bumper support and must be reinstalled.
I would actually try to make those plastic baffles (blue section) fit since they direct the air into the intercooler instead of letting it go around (path of least resistance)

 

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I would actually try to make those plastic baffles (blue section) fit since they direct the air into the intercooler instead of letting it go around (path of least resistance)

That's only 1 of the 2 sets of covers as well. There is a second set that is supposed to cover the endcaps completely so only the bars are exposed. Guess it's too big to fit them, just like my steamspeed IC.
 

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Discussion Starter #15
I would actually try to make those plastic baffles (blue section) fit since they direct the air into the intercooler instead of letting it go around (path of least resistance)

I can tell you the hard plastic portion (yellow) will not fit (without modification) with this intercooler. I reinstalled the soft plastic (blue) portion the first time and removed them the second time.

I may fab some diverters, but I might just leave it.
 

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I did ordered this intercooler.
But by the time I received it(overseas, Asia area) I was still sent with the exact package as you did. So there was missing bolt.
It’s lucky that my garage did have something that fits and we just install it without thinking of any missing bolt.

The intercooler was super heavy!


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