anyone have intercooler removal instructions?
You really should try to leave the 02's fitted in the cats on both removal and install. Unplug fittings at top in engine bay and unclip the wires from the stays (retainers) on lower inside of engine compartment (gently using a screwdriver to lever assist). Lower old system allowing wires to travel through the passages in the engine bay without snaring the end clips up on anything on the way through. Its much easier if you have a second person here to help here. On the way back up (on reinstall) get 4 pieces of stiff coated wire (@ 1.5 foot long) and coil the coated wire evenly around the sensor wires so you can feed them back up the passages and easily fish them out from the top to plug back in etc. The stiff wires will make it easier to fish them up from the top of the engine bay without bending the otherwise floppy 02 wires too much. If you dont need to remove the I/C's then best dont. It's only if you can't access the top nuts from not having the correct spannners that you will have to take off the I/C's unfortunately. The I/C hoses use snap lock wire clips, release clips by pulling gently back against the hose and use a small flat head screwdriver and lever the clip wire a touch at the rear enough for it to jump back and unlock. After disconnecting all the hoses then undo all the body nuts holding the I/C brackets to the car. Wiggle the I/C's about a bit to and then slide the very top of the IC back toward the rear of car by 10mm or so. This will release the top of the intercoolers intake vent from the body vent slot on the cars body. Only then will come away from the body of the car. Carefull tho.......nice and easy.
See how you go.
Forgot to mention when reinstalling the I/C hoses make sure each rubber hose fits back precisely into its exact slot in its female hose tube internally (if you look closely you will see there is really only the one correct position and it can be missed if you are not carefull) and, that the clip lock wire is properly locked into correct position or the hoses will blow off under boost . Suggest that you wiggle and pull back against each hose once its re clipped so to make 100% certain they are properly locked or you will be revisiting this soon after test drive
.
See how you go.

Forgot to mention when reinstalling the I/C hoses make sure each rubber hose fits back precisely into its exact slot in its female hose tube internally (if you look closely you will see there is really only the one correct position and it can be missed if you are not carefull) and, that the clip lock wire is properly locked into correct position or the hoses will blow off under boost . Suggest that you wiggle and pull back against each hose once its re clipped so to make 100% certain they are properly locked or you will be revisiting this soon after test drive
.
Last edited by speed21; May 29, 2010 at 08:03 PM.





