New Intercooler O-Rings fitted Viton CDT/CDTI.....................

By Arctic

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

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instructions. Neither 75ZT Community or the author of this document shall be held responsible for any losses or injury caused by the use of these
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Next bend the hose underneath the intercooler joint photo 3

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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.

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instructions. Neither 75ZT Community or the author of this document shall be held responsible for any losses or injury caused by the use of these
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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

Disclaimer: This document is intended as a guide only. You assume all responsibility for any problems howsoever caused as a result of using these
instructions. Neither 75ZT Community or the author of this document shall be held responsible for any losses or injury caused by the use of these
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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

Disclaimer: This document is intended as a guide only. You assume all responsibility for any problems howsoever caused as a result of using these
instructions. Neither 75ZT Community or the author of this document shall be held responsible for any losses or injury caused by the use of these
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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

Disclaimer: This document is intended as a guide only. You assume all responsibility for any problems howsoever caused as a result of using these
instructions. Neither 75ZT Community or the author of this document shall be held responsible for any losses or injury caused by the use of these
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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 Vaseline with the extra room now hose is not fitted pop the
elbow back into place lining up the elbow bracket hole photo 13

Disclaimer: This document is intended as a guide only. You assume all responsibility for any problems howsoever caused as a result of using these
instructions. Neither 75ZT Community or the author of this document shall be held responsible for any losses or injury caused by the use of these
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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 valve joint tighten up both
jubilee clips refit sensor clip jobs done. taped up hose for more protection from rubbing on body.

Disclaimer: This document is intended as a guide only. You assume all responsibility for any problems howsoever caused as a result of using these
instructions. Neither 75ZT Community or the author of this document shall be held responsible for any losses or injury caused by the use of these
instructions
photo pic of location of O-Rings

Disclaimer: This document is intended as a guide only. You assume all responsibility for any problems howsoever caused as a result of using these
instructions. Neither 75ZT Community or the author of this document shall be held responsible for any losses or injury caused by the use of these
instructions