Thought I would share some pictures of my recent intercooler replacement. I changed the originals (both leaking) with a spare pair that I refurbished. I fixed up the spares with JB Weld (the pictures should explain the process) then pressure tested them to 30psi. I immersed the fixed spares in a water bath to check for leaks and kept the 30psi in each intercooler for about 15 minutes before concluding the repair was successful. I chose 30psi as my car runs approx 22psi with the MTM568 conversion, and this seemed a sensible margin over the max expected pressure.
Test equipment fitted to fully cleaned and degreased used intercooler.
Blue pen marks area where leaks found, notice that I pushed up the aluminium fins to allow the JB Weld to get all the way around the leaking areas.
JB Weld! TIP: Use a hairdryer or heat gun to make the mixed compound more ‘liquid’ – that way it fills all gaps much quicker!
1 end filled, just got 3 more to do. Each end takes almost a complete JB Weld kit.
Both coolers reconditioned and sprayed silver.
Pressurised to 30psi and immersed in water – no leaks or pressure loss after 15 minutes
The car is on the lift, starting to remove some parts! All 4 wheels are off because I was doing some other work at the same time as the cooler swap.
With the wheel arch lining removed you get a good view of the inside of the old coolers – there were oil stains on both sides, the drivers side more than the passenger side.
This is passenger side. As expected neither cooler would hold pressure after removal and testing.
Bumper removal.
All of this has to come off! It has to be noted though that this is a very simple job, however having a car lift helps immensely.
Passenger side ready for replacing
Drivers side ready for replacing
Everything off, brakes stripped as well as I was going to paint the callipers a brighter colour.
Yellow calipers
Refurbished coolers fitted
Refurbished coolers fitted
All ducting re-fitted
All ducting re-fitted
View from underneath, ready to refit lights, bumper, wheel-arch linings, under-tray etc
Finished – VERY noticeable improvement in performance from car... I always thought the car was fast but after this repair the performance gain astounded me!!!