This is the third time the O ring for the intercooler to the throttle body has blown off. Any tips in keeping it on? (This is a brand new O ring).

 

Sounds like the intercooler is not square to the throttle body. If it moves or rocks on the mount it will pop them out. If you are using the Andial cooler consider cutting the tabs and reposition them to mount. They are not in the correct position. I have run into this a couple of times.

 

Thx Stephen!

 

Getting this right is a real pain.
After swearing so many times I found the solution that works for my stock intercooler.
I no longer blow the o-ring and installing the intercooler is so much faster, works every time.

I found that the mounting on the right side of the intercooler was a bit to high on my car (only a few milimeters), it was hard to get the intercooler all the way down on the throttle house. I way to check this is to remove the bolt completly on the right side of the intercooler when installing it. I used a Dremmel tool to get a lower mounting point.

 

Well I not only blew the O ring off , the boot from the CIS unit to the turbo came off. So some advice, when taking off the intercooler check all of the other boot and hose connections to make sure there is no other leaks.

Stephen great advice on cutting the tabs! It sits perfect now.