My new intercooler arrived and I took a peek at the manual to get an idea what I'm in for but it's pretty dry. Remove this, reinstall that. I know a bunch of you have done this job ..... some several times. Any info you can give me that's not obvious? Where does the sealant go, exactly. Any tips will be appreciated. Oh, photos of Rob's MB thermal coated I/C.

Les

 

sealant goes on the intake side. let it get tacky. watch how you route the purge valve lines they go in between the i/c and the s/c be very careful NOT to drop the mounting bolts into the engine valley!! use a magnet. the 2 mount bolts in the front will be diffucult with the i/c lines installed. the fittings on the i/c get in the way when aligning the bolts in the hole. dont strip or crossthread them . you may want to remove the fittings and reinstall them later

 

This motor is thought out so well its a breeze to work on. Replace the metal gasket under the lift ring in the back passenger side. Use the Merecedes sealant on the ic, you will see how they did it when you pull it apart.

 

The hardest part for me was pulling the fuel rail up and off. Hint, removing the black cover from the brake booster push lok will give you just enough room.

 

Notice the RTV on the edges of the gasket...

 

Thanks for the info. It seems silly to ask but .... I'm assuming the supercharger and intercooler come out as one unit and I can disassemble and assemble it on the bench. How heavy is the assembly? approx. (old back, weak mind at work here) I've been advised to expect 6 hours without complications so I'm giving it 2 weeks. J/K. Anyone run a meth line under the works? It seems like a good time to do it, don't you think?

Les

 

It's not too heavy. Put some moving blankets on your fender so you can brace yourself against it.

 

I wouldn't install any type of jet (nitrous or meth) into the intercooler due to lack of accessibility. The last thing you want to do is pull the SC to change jets.

 

I ended up putting the water/meth nozzle in the Y pipe. A test later today (tonight actually) is in the works to see if the boost prevents the sensor from seeing a drop in temperature. (I haven't sprayed yet after the change) The nozzle is flush on the inside of the Y and angled to spray in front of the IAT sensor. My fingers are crossed that it reads lower temperatures.

My old intercooler doesn't look too bad, perhaps all the spraying through the blower cleaned it up. So far my IAT's in traffic are the same as before, around 30º over ambient. On the highway they are more or less 20º over. More testing is needed before saying for sure.

It's logical, at least to me, to replace the I/C pump. 20º over ambient seems a bit high. So Rudy, pull the Pierburg or I'm ordering something else!

Les