S60 D5 185 Intercooler replacement

[outnumbered]

Fitting the poly bush will give you noise increase the footwell just for your info
Mike

[davebb]

Hi also I would look at the engine mount on the right hand side under the front pulley, it may look good but if you remove it and look on the sub frame if it needs changing there will be a outline were the rubber from the mount has been hitting the sub frame, ,
Dave

[Dazza95]

Originally Posted by Tunneruk

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!!

Glad to hear it went well. Would you say it feels quicker from a standstill? I have a slightly leaky intercooler on my S60 185 and it feels sluggish when moving off until you get close to 2k revs. Once you're up to speed it's fine.

[Tunneruk]

Originally Posted by Dazza95

Glad to hear it went well. Would you say it feels quicker from a standstill? I have a slightly leaky intercooler on my S60 185 and it feels sluggish when moving off until you get close to 2k revs. Once you're up to speed it's fine.

Absolutely, it's smoother and quicker right across the revs.

The intercooler I bought was brand new and £88 delivered (Ebay) and took me about 2.5 hours to swap in total.

That's less money than a tank of fuel and less time than the new poxy Mamma Mia film (so I'm told)

It's a bit of a no brainer when you look at it like that!

[Dazza95]

Makes sense, I don't have the confidence to do the intercooler myself but I've a very good specialist that I use so I'm going to get it booked in soon. I had the complete swirl throttle replaced a couple of weeks ago, apart from the intercooler, I've a small wiring repair to do on a couple of the injectors which I can DIY. I love the car and spend a lot of time in it so don't mind spending a bit to get it all working as intended.

[Tunneruk]

Originally Posted by Dazza95

Makes sense, I don't have the confidence to do the intercooler myself but I've a very good specialist that I use so I'm going to get it booked in soon. I had the complete swirl throttle replaced a couple of weeks ago, apart from the intercooler, I've a small wiring repair to do on a couple of the injectors which I can DIY. I love the car and spend a lot of time in it so don't mind spending a bit to get it all working as intended.

You might be surprised how easy doing the intercooler is, it's just nuts and bolts.

The thing to remember is to not try to cut corners to save time. If there's something in the way that you can 'just about' get past ... sometimes it's easier to just remove the obstructing part and continue easily rather than struggling to work around it.

My own personal tip .... and I use this frequently in my motorcycle restoration business.

When you take the car to bits ... put the bolts in two separate containers. One container is for the left side of the car, one is for the right. You'll be amazed how much easier reassembly is!!

[ma70]

Good tip, but I've fairly recently taken to threading fasteners back into their place to aid in not losing them and knowing where they go. Only takes a couple of seconds and no chance of knocking them flying out of a box. (the old grey matter's not as sharp as it was, used to just go from memory on even the bigger jobs)

[cheshired5]

The intercooler is definitely one of the easier jobs.
I prefer the from below method meaning no bumper/lights removal.

[jnmonaghan]

Originally Posted by cheshired5

The intercooler is definitely one of the easier jobs.
I prefer the from below method meaning no bumper/lights removal.

Hi Simon, Any plans to make a video to replace the IC using your Below Method?
Questions A) using your below method, do you remove the slam panel, the fan housing and can the radiator bolts be excessed easily? - Does the coolant need to be drained? And I take it, that the splash guard underneath the radiator pack, has also to be removed.
I have a stand up pit in the garage, which I think would assist in using the below method of IC replacement.
Thanks for all the very useful videos
My car is- 2003 D5 V70 with 122000 miles

Jude

[cheshired5]

Originally Posted by jnmonaghan

Hi Simon, Any plans to make a video to replace the IC using your Below Method?
Questions A) using your below method, do you remove the slam panel, the fan housing and can the radiator bolts be excessed easily? - Does the coolant need to be drained? And I take it, that the splash guard underneath the radiator pack, has also to be removed.
I have a stand up pit in the garage, which I think would assist in using the below method of IC replacement.
Thanks for all the very useful videos
My car is- 2003 D5 V70 with 122000 miles

Jude

Hi Jude, no video plans currently but this is my description of the procedure from another thread.
Radiator fan is removed but slam panel stays put.

Originally Posted by cheshired5

You will need to drain the radiator and disconnect all radiator and intercooler pipework, MAP sensor on the intercooler and the electrical connector on the ac receiver drier by the condenser on the driver's side.
You'll also need to tie up the condenser to the slam panel on the left and right so it doesn't fall out when the radiator pack is disconnected.