As a follow on to the triple intercooler o-ring modification i have recently undertaken a chance to do an update on how to fit the O-rings with out removing the bumper here it is below,a relaxing Sunday morning 20 minute job cheers Arctic.
Intercooler O-ring Change Without Removing The Bumper.
Tools you will need 8mm socket and a long flat blade screwdriver, some gloves and some rag we are now ready to start.
First remove the engine cover 3 8mm bolts Fig 1-2
1
2
Remove the cover and set it to one side safely with the bolts Fig 3
3
Next remove the 8mm bolt holding the coolant header tank to the fan cowling and put the bolt with the engine cover bolts try and keep every thing in one place less chance of losing them Fig 4
4
The next step is to loosen the jubilee clip attached to the EGR (CDT)Fig 5
5
With the jubille clip loosened you now lower the coolant header tank down and to the left, it as to lugs/pegs which fit into a bracket so easy Fig 6
6
The reason for lowering the header tank is it will give you more access to the 8mm bolt holding the intercooler bend to the side of the radiator shroud Fig 7
7
You can now remove the bolt with the socket Fig 8
8
You can now pull off the hose from the EGR which will need to be removed when you pull out the bend from the intercooler in the next process. Fig 9
9
With the hose released from EGR reach down and pull the hose upwards removing the bend from the intercooler Fig 10-11
10
11
With the hose and bend removed look down and you should see the stretched O-ring left behind Fig 12
12
Fish this out sometimes both o-rings can be left behing if the other one as swollen too Fig 13
13
With the O-rings removed clean out the recess in the intercooler wiping all oil traces away Fig 14
14
Now you need to remove the hose from the plastic bend and clean it remove the old O-ring if still attached and replace with the new viton O-rings you have purchased.
Now with the new O-rings attached to the bend and smeared with a little Vaseline/red rubber grease offer the bend back to the intercooler hole Fig 15
15
Make sure you hear a little thud when the bend is pushed home and that the fixing point is lined up with the bolt hole on the side off the radiator shroud Fig 16
16
Now you can copper grease the 8mm bolts thread and re-fit it securing the bend in place do not over tighten this bolts as yo can crack the plastic fixing point and it could snap later blowing the bend out of the intercooler believe me it can happen Fig 17
17
You are now ready to fit the hose back on the bend and EGR first make sure you have turned the jubilee clip round so the slotted end is facing up as opposed to side ways when you took it off. Fig 18
18
Push the hose onto the bend and the EGR and tighten the jubilee clip up Fig 19
19-20
20
Now tighten up the jubilee clip attached to the bend now you can see the reason for turning the clip round before, so you can tighten it from above on the right hand side below the head light remove the rubber cover from the back off the head light if you need to for more access Fig 21
21
Make sure it is tight Fig 22
22
You can now re-fit the coolant header tank locating the pegs into the fixing holes Fig 23
23
Fit the 8mm bolt again a little copper grease Fig 24
24
Header tank back in place all the is left is to fit the engine cover Fig 25-26
25
26
Job finished nice new tight viton O-rings Arctic :thumbsup