Intercooler - removal and refitting

1985 models Removal
1 Disconnect the battery negative lead.

2 Remove the air cleaner as described in Section 2.

3 Remove the intercooler upper and lower air hoses (see illustration).

22.3 Intercooler upper air hose attachment (arrowed)
22.3 Intercooler upper air hose attachment (arrowed)

4 Undo the upper retaining bolt, tilt the intercooler towards the engine at the top and lift up to disengage the lower retaining pins.

Remove the unit from the engine compartment.

Refitting
5 Refitting is a reversal of removal.

1986 models onwards
Removal
6 Proceed as described in paragraphs 1 to 3.

7 Undo the two radiator and intercooler lower retaining bolts (see illustration).

22.7 Intercooler mountings and attachments - 1986 models onwards
22.7 Intercooler mountings and attachments - 1986 models onwards

A Retaining bolts B Upper air hose

8 Move the radiator and intercooler assembly towards the engine and undo the four bolts securing the intercooler to the radiator.

9 Undo the retaining bolt and move the horn nearest to the intercooler to one side.

10 Withdraw the intercooler from the engine compartment.

Refitting
11 Refitting is a reversal of removal.

    See also:

    Water pump - removal and refitting
    OHV engines Note: A new gasket and suitable jointing compound must be used on refitting. Removal 1 Drain the cooling system as described in Chapter 1. 2 Slacken the three water pump pulley reta ...

    Weber 2V carburettor - adjustment
    Idle speed and mixture adjustment 1 Refer to Chapter 1. Fast idle speed (XR3 models) 2 Remove the air cleaner as described in Section 2. 3 Have the engine at normal operating temperature, with ...

    Instrument panel components - removal and refitting
    1 Remove the instrument panel. Panel illumination and warning lamp bulbs 2 Twist the relevant bulbholder anticlockwise and withdraw it from the printed circuit board on the rear of the instrument ...