I was trying to remove my intercooler at the weekend on my MY95
UK (angled type) but on removing the 3 bolts, loosening the large flexi pipe at the top and the jubilee clip which attaches to the turbo, it would still not come loose.
Am I missing something?
Any pics of similar year with I/C removed?
Cheers
Big Daz

 

I had exactly the same problem with my MY94 Daz, After struggling for long enough,I found another way around the job. I hope someone can give us the answer though.

Les

 

It just requires a bit of conviction !!!

Remove the bolts that hold the intercooler in place, loosen the jubilee clips around the intercooler to throttle body pipe, and loosen the jubilee clips that connect the turbo outlet to the intercooler pipe, also remove the dump valve from the turbo-i.c. pipe.

Now push the intercooler back towards the bulkhead (side to side) so that the front comes out of the pipe to the throttle bodie.

The next bit required brute force, I would suggest using a large screwdriver of break bar or similar. Where the turbo outlet goes into the pipe you need to prize this off, what i normally do is put a large screwdriver down the side of the pipe, wedged against the block etc and use this to prize the pipe away from the turbo, it will come off butbe careful that you dont split the pipe at the end.

R.

 

Had a wimpy go at trying this but didn,t want to break anything, also didn,t know if it would go back on again !!!
Guess I will just need to be a bit more persusive with the screwdriver.

Cheers
Big Daz

 

Another way which i found less distructive is to undo the 3x10mm bolts that hold the bottom pipe to the underneath of the intercooler, once these are undone and the throttle body pipe is undone the IC will come straight off easily.

Rob

 

How do you get to these bolts?
I could feel them with my fingers (what else ?) but could not get a spanner to them.

Big Daz

 

10mm spanner to do the two bolts on the passenger side and a 1/4drive ratchet with short extension to do the one drivers side bolt.

Rob

 

Tnx Guys

Les

 

Yes Cheers Lads,
Will have another go this weekend with more confidence now

Big Daz

 

did mine the other week,just a thought,why not get some samcos on while the coolers offi faffed around for ages trying to get it off, in the end brute force won,i pulled it as hard as i could and it just popped off,i however, flew across the garage.when putting it back on heat the throttle body (rubber) pipe under some warm running water to get it malliable

[Edited by care3 - 5/27/2003 5:09:33 PM]