with a shroud and SPAL fan. Not sure I did it he best way but here goes...
Bought off Ebay for £119 icl delivery I receibved what I belive is the uprated version which has improved clips etc.
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler001.jpg)
After chatting on the forums I was convinced to buy a shroud and SPAL fan which I bought from GTS_Chris for £70 incl delivery.
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler003.jpg)
I started this job thinking it was going to take me about 1-1/2 hours max - how wrong was I! :-( LOL
Remove the drivers side engine access cover by removing the 2 bolts:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler008.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler009.jpg)
Remove the X-brace by undoing the the 2 bolts and nuts on each side:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler014.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler015.jpg)
Loosen off the clips on the intercooler pipes and remove the pipes - can take a bit of wriggling to remove!
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler005.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler007.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler010.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler011.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler012.jpg)
Loosen off the bolt securing the Oil dipstick for a bit of extra access:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler022.jpg)
Once the pipes are off unclip the fan connector and remove the 3 bolts to remove the fan which should just then pull out:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler021.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler018.jpg)
Undo the bolts securing the top intercooler bracket:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler024.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler025.jpg)
I dont think you can even see it properly on this pic but remove the bolts securing bottom of intercooler (you need to use a ring spanner for this and its a bit of a pin to do):
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler028.jpg)
To give you more space remove the 4 bolts holding the engine hanger on and remove hanger:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler029.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler030.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler031.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler032.jpg)
Again to improve access remove the 2 bolts securing the pipe that runs across the top of the intercooler and twist it out of the way (still connected):
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler026.jpg)
So far so good - now this is where everything went downhill..... :-(
I tried to remove intercooler thinkinbg it would come out now but first problem was that it still appeared to be stuck at bottom to a bracket with completely inaccessible bolts. Eventually I removed the drivver side 1/4 air vent and using a ring soanner with lots of patience undid the 2 bolts securing the bottom of the intercooler (notice the spare wheel I was using to stand on - when working on your engine for some time its a killer for the back leaning over!):
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler046.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler034.jpg)
I wasnt really getting anywheree still so decided to undo the 3 bolts holding the shroud on to try and intriduce a bit more flex into the situation. The top 2 werent too bad but the bottom is almost invisible and involves lvereing away the shroud to the pint of almost damaging it then undoing the bolt - again with a spanner passsed through the 1/4 air vent.
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler034.jpg)
Well after a lot of messing etc I finally managed to wrangle the thing out - took me ages but if you persevere it will come out - not an enjoyable job though! The shroudd should then come out too. Should be left with an nice empty gap:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler042.jpg)
Fitted the shroud resuisng 3 boths that held cooler to bracket:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler045.jpg)
Trial fitted the interccoler which goes in and out easily when fan is not attached:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler043.jpg)
Next problem I has was trying to work out which pipes/hoses went together to join up the intercooler - found it harder than doing a rubiks cube! LOL Anyway once I had worked it out I acually connected up all the pipework uninstalled so access with spanners wasnt a problem. I suggest first you do a dummy run without any clips so you can twist it all around easily so the pipewok lies comfortably.
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler047.jpg)
Put the back pipe on before fitting fan and make sure the clamp bolts arnt going to interfere with the fan mount bracket.
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler048.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler050.jpg)
Bolt upthe fan to the mount with the bolts supplied in the kit:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler051.jpg)
Bolt up the 3 bolts to secure the fan and mount to the intercooler. When I had to reput it on due to a pipe blowing off I followed a tip to use tiewraos instead but I have found that it moves about making a scrapoing noise whn you go over bumps so I'm going to put the bolts back when I get chance.
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler067.jpg)
I found that the bolts supplies in kit werent much use as they were allan key and the washers wernt big enough for the intercooler brackets (on right) so I reused the existing intercooler bolts (on left):
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler055.jpg)
The other problem was that the connector on the SPAL fan didnt match the original Toyota connector :-(
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler063.jpg)
Rather than ruin my existing wiring by cutting it - or the fans I used a screwdriver as a lever to force the tabs down in the fan flug then pulled the tabs out the connector. With a bit of judicial filing I could then plug the 2 tabs into the original connector- SHOWN BEFORE THEY WERE INSULATED BTW!!!
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler064.jpg)
I'm quite lucky as the previous owner had fitted an override switch to make the fan come on all the time so with the fan on I held a tissue up the vent to make sure that it was sucking not blowing - the tissue was duly sucked up the vent. Also, use a tie wrap to secure the wiring out of the way of the alternator belt so it doesnt get damaged.
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler070.jpg)
Reinstall the engine hanger bracket you removed and also put back the pipe that runs across the top of the intercooler.
Assemble and connect the top pipe up:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler061.jpg)
The clips that come with the kit have come in for a lot of criticism in the past but they looked ok - the only problem I had was that one of ythye clips was just too small so had to re-use one of my old jubilee clips which was a bit annoying:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler058.jpg)
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler059.jpg)
On the whole the clips seem ok but I did have one blow off the enext day which was the bottom one at the back - typical! which I retightened as much as I dare without problem so far.
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler066.jpg)
Just reassemble any other bits ie. cross brace and engine access panel. Should be left with these bits:
![Image](http://i68.photobucket.com/albums/i2/jeffreyduckworth/Intercooler044.jpg)
Must admit its a pretty horrible job removing stock intercooler but you just have to persevere. I also strongly recommend you get a something to prop the engine lid up so you dont have to use the normal engine lid prop as otherwise it is constantlt in the way.