Re: how do i bleed the intercooler
IMO IC flow should be thus:
Out of the IC rad into the pump (factory) then from the pump to the bottom of the IC. Out of the top if the IC back to the top of IC rad. This is, in effect, the same routing that your coolant in the engine uses. The idea is that heat, and air bubbles, rise so we're not trying to pump against that. It can still be difficult to get all the air out of the system. Make sure, with the pump on of course, you can see water being pumped when you open the IC cap.
The way I've bled mine is to make sure IC is full, run the pump, (sometimes I had to turn it off and on a few times time to pick up prime) and just watch. As the air slowly works its way out of the system you'll need to add more coolant and will see more movement until you can't add any more.
"not running a cat"
I've not experienced it personally but the almost universal word here is; stock turbo + no cat = boost spikes.