AS51 – D3 TDV6 Fast Road Intercooler Kit
Remove the bumper; crash bar; ducting and original intercooler into original hoses
The new intercooler is designed to fit directly
And designed to mount to the original chassis crash bar captive fixings
Use the spacer plates supplied to slip behind the crash bar when re-fitting.
Re-assemble the vehicle as per manufacturer’s procedure.
Packing List
Intercooler + 2 x Bumper spacer plates
1. Remove grille and headlights
2. Fixings
There are a number of fixings which are not immediately obvious. Please check the manual if unsure.
3. Inner arch and trim securing screws and clips
Inner arch and trim securing screws and clips
Inner arch and trim securing screws and clips
Inner arch and trim securing screws and clips
Inner arch and trim securing screws and clips
Inner arch and trim securing screws and clips
4. Remove cowl securing screw
Use an 8mm flexible driver to remove the Cowl securing Screw.
5. This is the fixing removed using the flexible driver
6. Disconnect the wiring...
7. ...and headlamp washer pipe
8. Remove the washer bottle securing bolts
9. Remove this cover held on by 4 pins
10. Remove the crash bar
11. Lift out the intercooler duct
This is not required again.
12. The next step is to remove the original intercooler
This is secured with two plastic push-out pins at the top of each end plus the boost hose jubilee clips. It is a tight fit and will require some “wiggling” to remove it! You can see these mounts in later pictures.
Unclip the oil cooler if fitted, this can be cable tied to the duct on the rear of the new intercooler.
13. Carefully slide the new intercooler into position
14. Tighten the bumper bar bolts
15. Bar refitted with spacer
16. Relocate the air temp sensor here
17. New position for air temp sensor
Notice the pin mounts securing the original intercooler