Another job sorted today i replaced the intercooler O-rings with the Viton rings very easy job 45mins in total and that was taking photo's.
The intercooler is located at the bottom of the main radiator, and this is how it is possible to replace the O-rings with out taking the bumper off, by removing the push in elbow.
First locate the jubilee clip on the right in photo 1 and loosen then remove the hose photo 2
Next bend the hose underneath the intercooler joint photo 3
Now push hose down a little further photo 4
This will give you access to the bottom jubilee clip photo 5 as you can see the jubilee clip is facing the wrong way to undo.
But lets not panic a little further in and up to the right is the nut fixing the push in elbow to the car this is what we need to undo and remove photo 6
With the hose bent back you can insert a socket onto the nut photo 7
This then can be undone with a socket ratchet or in my case a bendy socket piece both will do the job photo 8 (nut is 8mm)
Once removed you can now pull up the elbow with hose attached and feed backwards out of the engine compartment you may want or have to unclip the sensor wire on the joint in photo 1 i did it helps just that little more. Now removed and away from the car inspect and clean hose and elbow remove the old rings photo 9 note how it as enlarged
After cleaning and inspecting the hose i remove the elbow so when i fit it back later i can set the jubilee clip facing up for easy removal next time if needed. At the same time note how the hose as rubbed on the car body and started to wear, i will now wrap this with insulation tape. photo 10
Photo 11 old and new rings top are old ones note how they have enlarged
New Viton O-rings fitted to elbow ready to be inserted back into it's radiator housing photo 12
Lubricate the new rings with silicone or in my case good old vaseoline with the extra room now hose is not fitted pop the elbow back into place lining up the elbow bracket hole photo 13
Insert 8mm fixing bolt tighten it up,photo 14
Then with the jubilee clip facing the right way up fit the hose to the elbow then to the EGR (Exhaust Gas Recirculation Valve) valve joint tighten up both jubilee clips refit sensor clip jobs done. taped up hose for more protection from rubbing on body.
photo pic of location of O-Rings
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