Guide : Removing an intercooler

JSeaman

SM Official Expert: Guide Author
SM Expert
May 26, 2009
216
0
0
Derbyshire, UK
Note that we have a rather strange intercooler in that the inlet/outlet are on the same side. You can uprate it and use the type that have the inlet/outlet on opposite sides but you need to do some fancy pipework and it's much easier with a front-facing inlet manifold.


Step 1 - Well, a crap picture to start but that's an intercooler (IC). This is an aftermarket unit so there may be some discrepency here but hopefully this will be of some use

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Step 2 - Undo the jubilee clip holding the IC pipework in place. Second picture shows you where the pipework is located (use a long extension bar to get through the grill)

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Step 3 -Jack the car up nice and high, you'll want enough room to drop the IC out from under the car

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Step 4 - Undo the 10mm bolts holding the plastic water cover in place (this is on the offside/driver's side). Don't forget the one on the side (second picture)

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Step 5 - You should now have a clear view of the IC pipework heading up into the wing

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Step 6 - If you are doing this after the turbo guide you will have already removed the other end of the IC pipework, if not then undo the 10mm jubilee clip at the other end of the pipe then remove it

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Step 7 - Remove the 10mm bolt securing the bracket for the IC in place

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Step 8 - Now remove the 10mm bolt holding the stabiliser bar to the oil cooler on

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Step 9 - Another 10mm bolt holds the bracket for the IC in place, remove it

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Step 10 - Ease the bracket clear so the IC can drop down

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JSeaman

SM Official Expert: Guide Author
SM Expert
May 26, 2009
216
0
0
Derbyshire, UK
Step 11 - Remove the coolant overflow reservoir, this pulls up although will give quite a bit of resistance until you graze your knuckles. Second picture shows the slidy bit

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Step 12 - Looking down from above the engine, remove the right hand bracket's two 10mm bolts

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Step 13 - Same again on the offside of the car

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Step 14 - Final retaining bracket is held on with another 10mm bolt

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Step 15 - Remove this bolt to disconnect the oil lines, thus allowing the rather large intercooler to drop on your face. This isn't a pleasant experience so try to avoid it

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Step 16 - The IC should now slide out from underneath the car. Here are a few pics of mine:

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