Yes, definitely packed in like Lego. That's a good way to put it. It's been a fun challenge to fit everything under the hood like I want. And things had to be done in a certain order to ensure it would all fit. For example, I had to mount the intercooler before I could mount the battery. And the battery tray had to be fabbed up before I could lay out the MAF sensor (once I knew it would all fit) and the combination of hard pipe and silicon elbows for the intake plumbing upstream of the compressor inlet.
I still have to install the windshield washer reservoir and the intercooler pump under there. I'm planning to put the windshield washer reservoir between the brake master cylinder and the battery. I'll likely need to remove the bracket that's spot welded to the shock tower and also modify the reservoir like I did the coolant overflow reservoir. I'll also need to extend the wiring for the front and rear pumps and the level indicator.
The intercooler pump will go under the Evo MAS, affixed to the frame rail. I will not be using a reservoir in the system. The heat exchanger I plan to use is the one found here: https://www.amazon.com/CXRacing-Exchang ... B07GGW3SST
It is a good match for the opening in the JDM bumper cover I still need to install. The controller I'm likely going to use to activate the pump (based on intake temps) is this one: https://www.amazon.com/12V-Mini-Digital ... B01J7VHS4I
I've done some (in my opinion, at least) creative problem solving. To get the compressor cover rotated so the outlet on the Green wasn't pointing down, I had to "massage" the water pipe and custom fabricate the wastegate actuator mounting bracket. I'll attach a photo so it can be seen between the radiator and the bearing housing.
I also had to change the angle of the thermostat housing outlet to fit the intercooler in there the way it is. Check the clearances on each side of the intercooler and you can see what I mean. It's about 1/4" max.
I mounted the intercooler on a bracket I fabricated that was the brace that attaches to the head on the intake manifold side on the 1.6 CSM's from the factory. It's that partially round, tube-looking brace that mounts to the transmission mount bracket. What that means is that the intercooler is hard mounted so that it moves with the engine. It's not mounted to the chassis.
I wanted to use the 1990 (?) NA throttle body with the integrated inlet so I wouldn't have to deal with the separate elbow. So that was cleaned and rebuilt with new seals. I deleted the coolant hoses going to the throttle body and the FIAV, but retained the ISC motor.
I made a catch can from two old brake fluid reservoirs. One is bonded to the lid so they can be separated by unscrewing them. I divided the housing and used some course steel wool. It can be seen zip tied in place to the left of the intake manifold.
I'm particularly pleased with how the OEM BOV mounting spot worked out. It's nestled in there just upstream from the throttle body with the OEM BOV flange mounted to the short section of intake plumbing. I have it recirculated into the section of intake just in front of the compressor inlet that has the gold heat reflecting tape on it. A lot of this stuff is hard to see since it's obscured by items above it.
The GM alternator is in there too. The info on line seems to convey that the stock adjustment bracket will work, and it will I guess. But I wanted it to be as much like stock as possible and the head of the adjustment bolt did not sit flat on the bracket face. So I did some welding and grinding and shaping to make it like the stock setup as much as I could. I also ran another cable to the battery from the alternator post.
I'll stop there for now and just add some photos.