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Originally Posted by Odd Job
I've replaced the top intercooler hose, the nice easy to see and get to one,
I was told by someone at the first Nano meet it was mullered, so I bought a new one pretty quick.
The inlet manifold and EGR has been cleaned out and I fitted new neoprene seals at the same time.
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I've not replaced the intercooler seals as I was told that it was nice and clean around the pipe, and there would be residue around the area if they needed changing.
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Double check the intercooler O-rings, remove the intercooler hose then remove the bend.
Replace the O-rings with Viton ones.
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Then pull the bend out of the intercooler.
once removed check that the old O-ring is not stuck in the intercooler,
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The O-ring on the end of the bend usually swells therefore does not seal, you can see the form this photo the difference.
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Clean in the intercooler hole with a rag, then fit new O-rings to the bend, add a little rubber grease to the O-rings and then refit the bend making sure it is fully pushed home, you should hear a little thud as it seats correct.
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replace the 8mm bolt, then fit the intercooler hose.
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The above only takes about 20 minutes and about £3 for the O-rings, so worth doing in my opinion.