I had good weather so I took the intercooler our for inspection today:
Remove the back panel - detailed here
. You will be left with:
Remove the rear crash bar. There are six T45 bolts holding the rear crash bar and rear valance mount holes. You will be left with:
Remove the TIK hose. There's a jubilee clip at the airbox and another at the turbo. Don't forget to recover the seal that goes round the turbo inlet. with the TIK removed, you'll see this:
Remove the exhaust. This helps a mile with accessing the intercooler hoses. Sorry didn't remember to take a picture of the car with the exhaust off.
Working from the top of the engine, remove the upper EGR valve intake hose:
Unplug the electric intercooler fan. Next, unclip the the wiring loom section that attaches to the fan. Next, using a pair of pliers or something suitable, pinch together the two tabs in the top middle of the cooling fan assy to pull the top of the fan assy away from the intercooler. Rock the entire fan assy forward and away from the top of the intercooler and the bottom fan clips will unclip - but be gentle with it. You will be left with:
Unclip the intercooler air temperature sensor connector from the bottom of the intercooler housing. Next, unclip the sensor from the connector coming from the wiring loom and set the sensor aside somewhere safe - it's fragile. The sensor is located to the lower left of the intercooler when looking from the rear of the car and looks like:
Remove the lower intercooler / EGR hose. First, unclip the circlip from the bottom of the EGR valve:
This picture wasn't taken in series, which explains why the cooling fan is still there! Next, undo the jubilee clip on the hose at the intercooler end. Finally, manipulate the hose out of the EGR valve then off the intercooler. The part looks like this:
Remove the lower intercooler / turbo inlet hose. Undo the jubilee clips at both ends and manipulate those out. This one is a royal PITA to get out by the way! It looks like this:
Phew - finally we get to remove the intercooler. It is secured by four plastic clips on the top and bottom of each side of the intercooler. You need get a thin flat bladed screw driver and carefully press it in to the centre of each clip to disengage it from the plastic housing. You'll see what I mean when you get there. Disengage each clip from the sides of the intercooler and *gently* pull it forward. As with the cooling fan, pull the top of the intercooler forward and away from the rear housing first. You can then manipulate the intercooler up and out of the engine bay. Be careful not to damage the semi rigid diesel fuel return line or any of the wiring loom parts as you remove the intercooler. With intercooler out, you will see the air scoop housing as shown below - with the plastic clips that engage with the intercooler also shown:
That's it for the moment as I have to dash out. I've got more pictures and information concerning the nature of the oil leak from the intercooler and the vibration damage / play issues relating to the air scoop housing against the intercooler and also what I've done to hopefully stop both the leak on the current intercooler (hopefully) and prevent the air scoop assy from fouling this and any other intercooler I put in the car!
Edited by kayble, 13 April 2009 - 10:55 AM.