S60 D5 185 Intercooler replacement
 

My 2005 Phase 2 S60 D5 needs a new intercooler. I'll bite the bullet and buy a new one.

I can't find a 'How to' on replacing the intercooler.

Can it be done easily or is it a full 'bumper off' jobbie?

https://www.youtube.com/watch?v=EL8hkRS_2LM

https://www.youtube.com/watch?v=XNOZifX4aGg&t=7s

Make sure you get the right intercooler as per the first video from Simon and fitting it is pretty straightforward.

Nissen are reputed to be good. Can be got on Ebay.

It's started!

https://farm2.staticflickr.com/1843/...5a1d5acc_b.jpgIMG_9320 by tunneruk, on Flickr

I wish I had your energy!

So do I .... it's all gone now :teeth_smile:

That said .... I wasn't posting on this forum at 2.51am this morning :tongwink:

So back down to my workshop bright and early ....

30 minutes later and the intercooler was out ...

https://farm2.staticflickr.com/1860/...6c0f60f4_b.jpgIMG_9325 by tunneruk, on Flickr

I plugged up the ends and ran 30psi into it ... it's absolutely like a piece of Swiss cheese. I counted 16 separate leaks before I stopped looking :eek:

What is quite encouraging is that although there is some oil residue on the outside of the cooler built up over 13 years, the outlet pipe into the intake system is surprisingly dry. It does explain why the EGR wasn't gunned up in the slightest, just a light film of dry soot.

https://farm2.staticflickr.com/1871/...d8351171_b.jpgIMG_9333 by tunneruk, on Flickr

https://farm2.staticflickr.com/1877/...b75f4f09_b.jpgIMG_9330 by tunneruk, on Flickr

https://farm2.staticflickr.com/1849/...93482d6e_b.jpgIMG_9334 by tunneruk, on Flickr

To quote one of my current favourite Youtube mechanics, "There's yer problem, lady"...

Hope the new IC fixes all the issues, I have to imagine it's going to make a considerable difference.

I'm hoping so, I think it's going to go like a stabbed rat with the new I/C

yes it should be good,
mine was bulging the same but no leaks but I did change it as it was about to go, I replaced it with a high flow DO88 intercooler, this was before there prices went crazy,
good to see it is coming on well,
I also got some black wire mesh and fitted it to the front bumper air opening, to stop any stones from doing any damage to the coolers,
Dave

The conclusion ....
 

So my new intercooler arrived at about 1pm today.

While I was waiting for it to arrive I fitted the poly bush to the lower engine stabiliser which was totally shot ...

https://farm2.staticflickr.com/1833/...76d93f7b_b.jpgIMG_9318 2 by tunneruk, on Flickr

https://farm2.staticflickr.com/1897/...c3c2e65e_b.jpgIMG_9340 by tunneruk, on Flickr

https://farm2.staticflickr.com/1858/...f8d15823_b.jpgIMG_9341 by tunneruk, on Flickr

Then after Mr. DPD had visited I got straight to it ...

https://farm2.staticflickr.com/1831/...32f24810_b.jpgIMG_9342 by tunneruk, on Flickr

https://farm2.staticflickr.com/1834/...cc1cce29_b.jpgIMG_9346 by tunneruk, on Flickr

Made sure everything was tip top, plugged in the computer and cleared down all the codes and took her up the road ....

Jeez what a difference, not only did the new upper and lower engine stabilisers make the car feel so much smoother but the intercooler has made a massive difference in power delivery and quantity. It has effortless speed.

I did 50 miles on the motorway as which point I'm pretty sure the DPF did a regen (as it had been running really dirty before the intercooler) and that was that.

I put the cruise on at 75 and it's indicating 50.4MPG.

I couldn't be more pleased!!