Mine is also air-to-water. It's the heat exchanger that goes in front of the grille, which then moves the coolant to the aftercooler (superchargers don't have intercoolers) which is sitting on top of the throttle body.
The heat exchanger is about the size of the A/C condenser as well, so you're right, I may be able to do it without removing the grill.
Once I get it all tuned I'll post up some dyno numbers, but from what it looks like, I should be at about 250hp at the wheels, which is pretty good considering that the 4.0 puts down about 135 (conservatively speaking) at the wheels stock.
Have you had any issues with yours overheating with the intercooler in front of the radiator? I bought the 1602 CFM Spal fan to push as much air as I can through there just incase. I shouldn't have any issues, as this fan moves a lot more air than the one that typically comes with the kit.
I'm still running the stock radiator and fan, and have not had any cooling issues even on the hottest days. Here's a link to the
Banks Intercooler installation manual. It shows how to mount the intercooler radiator behind the grill without removing the grill. It may or may not be helpful with your setup.
Once you start compressing the intake air, you may want to start monitoring the intake air temp. To do that, I added a
ScanGuage. The ScanGuage plugs into the OBDII port and allows me to monitor any of the sensors on the vehicle. I set it to monitor coolant and intake air temps, instant mpg, and mph. (you can add a correction factor in the ScanGuage to compensate for different tire size. Now that I've added a SpeedoHealer, I don't need to monitor mph on the ScanGuage any more). You can also input the amount of fuel you add when you fill up, after adding that information a few times it adjusts the ScanGuage to give a pretty accurate mpg.
I custom mounted mine in the windshield header, which is easier than it sounds. Take off the visors and pop off the plastic cover. Trace the outline of the ScanGuage on the inside of the plastic cover and cut it out with a razor knife. Take your time and cut a little less than you think you need - you can always cut more but it's hard to put it back if you cut too much. Use a file to shave off material until you have the fit you want. What you are aiming for is a press fit where the ScanGuage is held tightly in place with no fasteners. Once you're satisfied with the fit put the ScanGuage in place and use a straight edge to make it flush with the plastic cover. Then on the backside lay a thick bead of black RTV silicone sealant - the press fit combined with the sealant will keep it in place over the roughest terrain, and the black sealant will hide any little mistakes in the fit. Pull the plastic cover off the driver's side A-pillar. Run the cable for the ScanGuage under the left side of the windshield cover and pop it back in place. Run the cable down the driver's side A-pillar and pop that cover in place. Pop off the plastic dash cover at the base of the windshield, run the cable down behind the instrument cluster, and put the cover back in. Then route the cable to the OBDII port and plug it in. Like I said, it's easier than it sounds, just take your time when cutting the hole for the ScanGuage to get the correct fit, the rest is just routing a wire behind plastic panels.
ScanGuage monitoring WaterTemp, IntakeAir, MPH, and MPG
Intercooler water radiator
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