urquattro20Vt

Been searching - can't find anything. Is there a good written intercooler installation procedure somewhere? The part I'm wondering about is getting the intercooler over the orange seal and seated properly on the throttle body..any tips or tricks??

Seems to me they should have used a very short connector hose....

Thanks.

Brandon
'91 911 Turbo
'01 Audi S4

Metal Guru

Hey Brandon,
Getting the intercooler over a new o-ring is an significant challenge if the o-ring is not well lubricated.
I'm able to get a water-based rubber lube called Merpol to assist. I soak the o-ring in a bowl of Merpol for a few minutes, install the o-ring and quickly install the intercooler. It takes a little wiggling of the intercooler to get it to slide down. There's a boss cast into the left side of the throttle body that is the intercooler stop. When the intercooler slides down far enough to contact it, the intercooler is home. You can look in with a flashlight to check that the intercooler is in contact with the stop.
Here's a source for Merpol: http://www.blasterstool.com/merpola-...antper4oz.aspx

H2O LOL

I lightly cover the IC and the oring with a little motor oil. Stay focused and wiggle it alot with a light hand. Seems to work for me. Good luck.

urquattro20Vt

OK - thanks guys. Sounds like I'm doing the right thing - just wanted to make sure. My o-ring is lubricated with something - looks to be red.

Thanks!

Brandon

H2O LOL

Once you get it lined up it take a good oomph to get it on there. It's a really good seal and when you get it on you will know its seated because the metal of the IC will hit and make a solid clued when it hits the metal of the TB.

urquattro20Vt

Yeah - I've had it off once before and got it back on. This time didn't go as smooth. Sounds like there isn't a real trick....

Does anybody ever cover the IC face with, say cardboard, then a large block of wood that would spread load, and then tap the wood with a rubber mallet to help "encourage" it?

Brandon
'91 911 Turbo
'01 Audi S4

Boeing 717

I just placed a hand on each side of the top and shoved it down. Worked umpteen times for me. It should take a firm nudge but I never needed a mallet or anything.

paul_boivin

easy peasy, just "wigle" it down, did the trick for me when I had to install it after removal

H2O LOL

You get your ignition issue worked out?

urquattro20Vt

YES!!!!!!!

but backtracking a little - I don't know if it made teh differnece - but i brought the IC inside my house and warmed it up (it was pretty cold outside) and also put the orange seal in hot water for a while - took it back out and it slid right on.

Thanks guys - igntion solution posted in my no-start thread.

Brandon
'91 911 Turbo
'01 Audi S4