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Old Sep 22, 2016 | 12:18 AM
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Billy22Bob
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Joined: May 2012
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Default Re: Leaking Intercooler

I have the same problem.
Make sure you dont have any leaks elsewhere first.
I think I have the same problem as you = having to add about 1/2 Gal every 1000miles.
But...found a weeping leak where at the resevoir where the top hose connects to it. I recently glued this all up and am waiting to see if that makes a difference.

If DIY
You have to remove the Supercharger...= 2 person heavy
see here for an example. The cooler sits underneath. You don't usually remove it like its shown in the photo - people normally take the air intakes and manis off and then remove the SC+IC as a unit.

I did read once of someone setting up a yoke of some sorts which sits on the strut towers and you can lift the SC out single handedly - otherwise an engine hoist would also do the job.

You will need new mani gaskets (upper and lower) at hand + the one for the SC>IC. Needswings sells a kit here. But you dont need the top one in the photo unless you are removing the SC inlet snout. The 12 o-rings also - I'm not sure what they are for.

You will need your Torx and Torque wrench with all the right numbers. Careful with the mani bolts - they are screwed into aluminimum - and many reports of people stripping these = disaster.

I suggest you consider executing the "baked potatoe wrap" at the same time if so inclined. Search this BBS to find out more.

I have a spare "pressure tested" 2nd hnd IC but am holding on it for obvious reasons.
Rudi also makes a flash replacement to order - search again - not sure if he is still offering the service.
If you talk to him - tell him Billy22Bob told you to order a copper one....;>)
 

Last edited by Billy22Bob; Sep 22, 2016 at 12:21 AM.
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