Changing the intercooler (from old site)

Changing the intercoolercontributed by Rich Russell

A simple 10 minute job, ideal for a beginner. Here's how to replace the standard item with an alloy one.


The intercooler is basically a box that the hot compressed air from the turbo flows through which is cooled by the air entering the front of the car. The result is cooler compressed air which is fed to the carburettor. The cooler this air, the more dense it is, hence more oxygen it contains per litre. More oxygen=more power!

The standard intercooler is fine for standard boost, but replacing it with an alloy one is a must if you're planning big boost...

https://www.rtoc.org/articles/i/inte...nter03_200.JPGThe intercooler is held in by a rubber strap and the two boost hoses.

https://www.rtoc.org/articles/i/inte...nter03_200.JPG Undo the two jubilee clips holding the boost hoses on.

https://www.rtoc.org/articles/i/inte...nter04_200.JPG Pull the hoses off the intercooler. You may need to lever them off.

https://www.rtoc.org/articles/i/inte...nter05_200.JPG Undo the rubber strap from the hook at the top.

https://www.rtoc.org/articles/i/inte...nter06_200.JPG Remove the two Torx bolts holding the hook and ram air intake on.

https://www.rtoc.org/articles/i/inte...nter07_200.JPG Then remove the hook.

https://www.rtoc.org/articles/i/inte...nter08_200.JPG Pull the air intake away from the front of the car.

https://www.rtoc.org/articles/i/inte...nter10_200.JPG Then move it out of the way. You may want to tie it so it stays put.

https://www.rtoc.org/articles/i/inte...nter11_200.JPG Pull the intercooler off the rubber grommets at it's base.

https://www.rtoc.org/articles/i/inte...nter12_200.JPG Remove it from the car.

https://www.rtoc.org/articles/i/inte...nter13_200.JPG The old intercooler next to a shiny new alloy one.

https://www.rtoc.org/articles/i/inte...nter14_200.JPG Put new intercooler into place and refit air intake and hook.

https://www.rtoc.org/articles/i/inte...nter15_200.JPG Refit the rubber strap and hoses. Be sure they're tight!

https://www.rtoc.org/articles/i/inte...nter16_200.JPG Check it's secure, then that's the job done!


The alloy intercooler will be able to handle more boost pressure, and cool the boost air more efficiently than the standard one.