Thread: Remove TD5 intercooler

Hi, bit of a job take your time and you will do ok. Don't forget the bolts behind the horns hidden by foam. I would also have a look in the intake manifold when you do the EGR removal. Mine was full of thick oil slurry. I ended up removing it and cleaning it with oven cleaner and a gerny took two goes before it was in a reasonable condition. Slow and steady wins the race.

I'm sure others have said the intercooler can be cleaned in situ

Yeah good luck cleaning it in situ...
easy job to remove and you get a far better result imho.
Definitely clean the inlet manifold out too if you can, my first one soaked in degreaser overnight, wasn’t super shiny in the morning but after some encouragement with the karcher it was pretty clean inside.

I cleaned mine a while ago and took it out completely. But recently I changed a fuel pipe at the front of the head and instead of taking off the inlet manifold to get to it I opted to take off the fan and egr cooler to get to it. I remember looking at all the room in there with the fan off, and thinking wow the intercooler would have come out in 5 seconds if I had have taken the fan off too. Worth thinking about.

Originally Posted by hpal

I cleaned mine a while ago and took it out completely. But recently I changed a fuel pipe at the front of the head and instead of taking off the inlet manifold to get to it I opted to take off the fan and egr cooler to get to it. I remember looking at all the room in there with the fan off, and thinking wow the intercooler would have come out in 5 seconds if I had have taken the fan off too. Worth thinking about.

And I have a set of fan spanners. Thanks for the intel. This just the type of info I was looking for.

Thanks

Julian.

Good tutorial here www.discovery2.co.uk / Workshop / Intercooler Cleaninr

Can be done with the fan in place but soooo much easier without

Urban Panzer leaves the battery in and the fan in. I'll remove the fan.