took my intercooler off today (MY99) to fit senders for my defis and the bloody thing wont go back on!
i cant get the plastic hose to go back onto the turbo outlet, scraped knuckles, much effing and blinding and two hours later still wont go!
any suggestions?

 

Try this ?
Looking from the front remove the right hand ic support bracket,
slip the throttle body hose onto the neck and slacken the clips right off and push them up the hose and leave the top right hose off,
Tighten the rear bottom 2 hose clips on the ic 3 branch hose and slacken the hose clip right off and slide the hose clip up the pipe for the turbo flange and stick sum lube on the inside.
Then slip the cooler in at an angle from the back pushing the turbo hose on first then slipping the ic into the throttle body hose,Maybe good time to get someone to hold ic in place while you pull the hose clip up onto the turbo flange and tighten it.
The rests easy

 

i'll try that tomorrow! had enough for today, so its off to the pub!!!

 

wipe some vaseline or something else thats slippy inside the hose, it will help it go on. can be a pig if you try to do it without.

 

tried the mrs lubricant, now thats slippy!!!!!
still didnt work lol

 

I had the same problem recently, I couldn't get the [#&@!] plastic hose back on. Solution #1: Hot air heat gun! Problem solved in 5 seconds, the heat makes the plastic more flexible.
Solution #2: I've purchased a set of Samco silicon hoses

 

Had exactly the same problem! Run the intercooler piping under hot water and it will slip back on, no problem. I still have the bleeding knuckles after trying to get mine back on!

 

the "old" hairdryer/hot air gun trick is the almost guaranteed way if its a bug*er.........................

alyn - asperformance.com