300Tdi Defender
19
FUEL SYSTEM
16
REPAIR
INTERCOOLER
Service repair no - 19.42.15
Remove
1. Disconnect battery.
2. Remove 2 nuts securing fan cowl to radiator top
cover.
3. Remove 4 bolts securing radiator top cover to
side covers.
4. Remove 2 bolts from both sides, securing
radiator top cover mounting brackets to bonnet
platform.
5. Detach radiator top cover, complete with
mounting brackets.
6. Slacken retaining clip and disconnect top hose
from intercooler.
7. Slacken 2 clips and disconnect bottom hose
from intercooler.
8. Manoeuvre intercooler upwards and remove
from vehicle.
9. Check condition of foam pads fitted to top and
bottom of intercooler and renew if necessary.
10. Check condition of intercooler locating grommets
in radiator top cover and renew if necessary.
Refit
11. Manoeuvre intercooler into position at LH side of
radiator.
12. Carefully lower intercooler and locate bottom
lugs into radiator bottom support frame.
13. Fit bottom and top hoses to intercooler.
14. Fit radiator top cover and secure mounting
brackets to bonnet platform.
15. Secure radiator top cover to side covers.
16. Fit fan cowl to top cover.
17. Reconnect battery.
