Engine/Transmission (1994 - 1998) Intercooler Removal

[BHuebner]

Do you need to pull the front bumper to remove the intercooler on a 95? i tried to remove it when taking out the radiator last summer. pulled the top brace off the front, but the tabs on the stock intercooler kept it from coming straight out the top and the condensor seemed to get in the way as well. seems like a pain in the a#@ to remove the bumper. thinking of installing a piers or spearco help keep the egt's down.

 

[Joseph Donnelly]

You need to remove the bumper, radiator, top brace with the 45 degree angled struts going to the lower support. Either remove or swing the condenser out of the way. The intercooler inlet and outlet pipes are wider than the upper parts of the bracing at the sides. Therefore, you have to lift slightly, and move one side of the intercooler forward, then work the other side out.



To remove the radiator, turn the drain plug and pull out. It helps to spray WD40 into the recess to lubricate the o-ring. If the o-ring on the plug tears, you will have to replace it to prevent a leak. The o-ring is 9/16” ID, ¾” OD, 3/32” thick. Then take the hoses off the radiator. To remove radiator and intercooler hoses, it helps to work a tool into the joint to free the rubber from the hose fittings. I like the Sears Craftsman cotter pin remover. It is like a blunt ice pick with the last inch bent at a right angle.

 

[BHuebner]

thanks Joe,

i was afraid of that. (bumper removal). ive heard that the intercoolers out of the 24v flow better. do you know if this is true?

 

[PRattenbury]

Bumper removal is nothing to be intimidated by. I take them off by myself in a few minutes. 8 or 10 bolts and you're done. Getting it back on requires an extra set of hands to get it adjusted right again.