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Intercooler removal

So, I decided to remove the intercooler to clean it out.
I have the nose panel off and the intercooler is loosened. I see I need to remove the plastic duct in front of the IC before it can be removed.
How is the duct removed?

Cheers,
Michael

check the <a href="http://www.lindseyracing.com" target="_blank">www.lindseyracing.com</a> website. there is a full procedure there!

There should be a couple small screws that hold it to the intercooler. Remove the screws and it should come right off.....

You can clean the IC with it in the car a lot easier & quicker. Go to Home Depot and get two PVC 90 degree elbows. Bring the IC hoses with you...but I think it's 2.5 inch fits the IC hoses perfect. Then angle them upwards, tighten clamp and fill with water & cleaning solution. I used the purple Castrol stuff. Agitate with comressed air if you can. Then cap one end and suck out the solution with a shop vac. Then flush with water a few more times. Get your wife/girlfriends hair dryer to speed up the drying process.

I just installed a Lindsey stage 2 intercooler this weekend. Their instructions are not clear on getting the intercooler out.

I removed the two funky screws (had to fabricate a custom screwdriver) that hold the intercooler duct. I then tried to remove the duct first to give the clearance needed, to get out the intercooler. This did not work, the duct will not come out.

I then attempted to remove the duct and intercooler together. This also did not work.

I finally folded in the sides of the duct and wrestled out the intercooler leaving the duct in place.

Moral of the story, the duct stays. Fold in the sides of the duct and semi-force the intercooler out by rolling it up and out. Then semi-force the intercooler back into place.

Hopefully the sides of the duct will eventually go back to their original position and cover the entire intercooler.

Bill has the right idea, that's exactly how I got mine out yesterday, leave the duct in place, rotate up and pull. It's not hard in the end, you just have to get the right ammount of rotation vs. pulling. The duct gets smashed a little bit, but it's plastic, so it'll live :)

<blockquote>quote:<hr />Originally posted by Bill:
I just installed a Lindsey stage 2 intercooler this weekend. Their instructions are not clear on getting the intercooler out.

I removed the two funky screws (had to fabricate a custom screwdriver) that hold the intercooler duct. I then tried to remove the duct first to give the clearance needed, to get out the intercooler. This did not work, the duct will not come out.

I then attempted to remove the duct and intercooler together. This also did not work.

I finally folded in the sides of the duct and wrestled out the intercooler leaving the duct in place.

Moral of the story, the duct stays. Fold in the sides of the duct and semi-force the intercooler out by rolling it up and out. Then semi-force the intercooler back into place.

Hopefully the sides of the duct will eventually go back to their original position and cover the entire intercooler.<hr /></blockquote>So did you have a chance to try it out yet? How do you like it?

I remember doing this a while ago. Took me a while to get it out but it was full of gunk from el-turbo so it was good to clean it. Getting the little screws out is a pain and I think I didn't put them all back in - I think they're inside the duct. The duct is flexible enough that you should be able to bend it out of the way and get the IC out. That's what I did. Careful though - bend it gently.

<img border="0" alt="[cheers]" title="" src="graemlins/beerchug.gif" />

I did this over the weekend as well. On the '87 there are two plastic nuts holding the bottom of the vent to a couple studs mounted on the chassis. I think they are 8mm, and you can reach them through the vent opening with a 6-8" ratchet extension. You still can't remove the vent, but it frees it up a little more to make a difference.

If you live somewhere cold, run a heater on the area first so you don't break the plastic. It does seem pretty flexible, though.

Ron

<blockquote>quote:<hr /> So did you have a chance to try it out yet? How do you like it?
<hr /></blockquote>Tazman,

I will not be able to run my car until I put the engine back together. I blew the headgasket. I had Lindsey Racing do some headwork (exhaust ports)and O-ring. I am waiting for my ceramic coated exhaust to come back from HPC (should arive this week) before I can put it all back together.

I do like what Lindsey did with the intercooler. The stage II modification, cuts off the end tanks and replaces them. The stock ends have a very restrictive inlet and outlet. With the choke points removed, the intake air velocity thru the intercooler should be slowed, which should reduce the charge temps. Lindsey claims a 150 degree reduction.

A reduction in the intake charge temp is my main reason for changing out the intercooler. Less charge temp should equal less chance of detonation. I also am going to run 18psi of boost and when you add boost, you add heat. So I need to remove the added heat.

However, after inspection of the headgasket, I believe the cause of the failure was my head lifting and not detonation. The #4 cylinder gasket ring was egg shaped with a grove pushed out from the cylinder.