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  1. #1

    Join Date
    Jul 2005
    Location
    Powhatan, VA
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    281

    RXP Intercooler 101 Help

    Trying to pull my intercooler and it will not come out. It has about 1/4 in. play and sounds like it is hitting inside about half the distance back towards the TB. Anyone have this problem or a solution?
    Thanks


  2. #2

    Join Date
    May 2005
    Location
    biggs ca.
    Posts
    150
    They come out real hard there is a compressed O ring on it.

  3. #3

    Join Date
    Jul 2005
    Location
    Powhatan, VA
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    281
    I got it. Rubber hammer and round brass punch on the lip.
    Thanks

  4. #4

    Join Date
    Apr 2005
    Location
    Michigan
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    How do you remove it? Several of us have intercoolers being shipped to us right now. Any tips? I remember Hulk saying to put silicone on the block off "O" ring to stop it from leaking air.

  5. #5

    Join Date
    Jul 2005
    Location
    Powhatan, VA
    Posts
    281
    You will have to remove the seven intake manifold bolts to get it out. The gas tank is in the way to pull straight out. Not enough clearance. Make sure you get part of the intercooler out before breaking the manifold loose. You do not want that manifold flopping around. You will have to tilt the manifold to remove intercooler. It is possibly that if all the air intake box next to the gas tank is removed the intercooler will slide out. I have not removed mine so I do not know.

  6. #6
    Water4fire's Avatar
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    May 2005
    Location
    New Braunfels TX.
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    9,384
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    I used an old inner tube and cut out a big thick gasket and used it instead of silicone. It was very easy and mess free.

    I was able to take the stock IC out by tilting the intake allot to remove it, but it was a pain in the ass. I would recommend removeing the under seat vent and its down tube. That would make things a bunch easier.

    ..

  7. #7

    Join Date
    Jul 2005
    Location
    Powhatan, VA
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    281
    It was a pain in the butt. You got to have patience to work on this stuff.

  8. #8

    Join Date
    Apr 2005
    Location
    Michigan
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    274
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    Great.....Thanks for the advise! I'm sure the other guys will appreciate it too.

  9. #9
    Vern's Avatar
    Join Date
    May 2005
    Location
    Grand Haven, MI
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    3,571
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    I did not remove my intake manifold or even loosen it up. I just spent a little time turning, twisting, wiggling, and I got the stock intercooler out. I think the end rubber O ring fell off and I had to reach in and grab it, but other than that, it worked fine. I had to cut off a pretty small piece of one of the stock O rings to put on the blockoff plate ... that too took a little finessing on my 2005 (gaskets are different than on 2004s).

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