 | Home > Td5 > My second hand Intercooler repair |
 
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6037   
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You can do it with the bullbar in place, but it's fiddly. you'll probably gain time by removing it totally.
So, the 4 bolts (2 each side) that hold the bumper & bar in place, they attach to a captive nutplate which clips to the bottom of the bumper. Sometimes the spring bit of this rusts away, so when you take both bolts out, the plate falls off (easy to get, some long nose pliers and you can pull it out of the front of the chassis once the bumper is removed) When you re-assemble, it will take some fiddling and cursing to get the bolts to go through the nut plate. the tip is to be gentle, get the end of one bolt through the plate (nice coating of copper splip or grease helps for next time you need to remove it too). once one bolt is in, it's easy to get the next one one. When you're tring to get the first bolt in to the plate, don't push down too hard before the threads have "caught", otherwise you'll end up screwing the bolt in and just pushing the nutplate down at an angle. The 3rd bolt for the nudgebar will probably just go through the bumper with a nut on the back. this can stay in place, so the bumper and bar come off as one unit. this will make refitting easier (if not heavier!) as all the holes will line up. Once the bar is off, open the bonnet, prop the bonnet open with a broom handle (or just remove it totally) as you will need to remove the bracket that holds the bonnet support bar. take that plastic top cover off of the radiator (it has dzus type screws so only need to be turned 90 or so degrees to undo ) and take off the front rafiator grill (6 large cross head screws) the front panel that the rad grill screws to, needs to come off, so there is a lower bolt either side (usually 13mm) that goes through to the inner wing, under the headlight, you can reach your hand under with a spanner) and two top studs/nuts. sometimes the nut comes off, sometimes the whole stud comes out, doesn't matter. Then there's 4 small self tapping screws across the top. then the fornt panel should come away. leaving the two ^ shaped bars, again 13mm bolts on the bottom, and usually a 10mm bolt on top, which goes through the bonnet catch as well. Once that's done, 10mm bolts again, 3 either side, to remove the radiator top mounting brackets. as you look at the front of the vehicle, the LH bracket has the bonnet support rod on it. remove both of these. Then remove the intercooler pipes, one each side. There's 2 bolts that hold the intercooler to the main radiator (10mm I think) Then the intercooler should be able to be wiggled away from the main rad. Offer up the new intercooler, and see if the plastic tags need to be cut off of the main radiator. only about 1/2" of plastic needs to come off, you'll see them and it's pretty obvious where they are. then "simply" refit the new intercooler and the rest of everything in place. Job done.  |
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20th Jul 2013 12:18pm |
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| johnnyd Member Since: 13 Apr 2013 Location: Chippenham Posts: 1006 
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OK I am following the online pdf and Jamie's instructions but hit a snag....i seem to have two extra mounts on mine, one each side ?
 Click image to enlarge 2008 TDCi 2.4 XS CSW |
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20th Jul 2013 1:46pm |
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6037
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That's the bracket that I mentioned that's held on with the 3x 10mm bolts (and the LH one has the bonnet support rod on it)
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20th Jul 2013 1:59pm |
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| johnnyd Member Since: 13 Apr 2013 Location: Chippenham Posts: 1006
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Ah I missed that bit
Also these look like the original rad and intercooler, and the Fins are like powder in places, does that matter? 2008 TDCi 2.4 XS CSW |
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20th Jul 2013 2:09pm |
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6037
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In an ideal world, the fins would be perfect, but they do corrode away in time and turn to dust, as you see.
I'd put away a few pounds each week and keep an eye out for a new rad. They're not that expensive to replace. The only PITA, is you need to do all what you're doing now... again...  |
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20th Jul 2013 2:15pm |
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| johnnyd Member Since: 13 Apr 2013 Location: Chippenham Posts: 1006
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Fitted and wow....big difference even without a new mapping, that comes tomorrow
Thanks for your help Jamie
Quick question, i cant get the metal surround back on(it was a  to get off) as two lugs at the top seemed to slot in behind the bar brackets, do i just cut the lugs off?
Edit.....I cut them off one thing has occurred though, the left retaining nut to secure the metal surround has dropped of into the headlight housing, so the grill now wobbles on the left, any ideas how I can get another nut in that headlight housing?
JD 2008 TDCi 2.4 XS CSW |
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20th Jul 2013 5:06pm |
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