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900 Turbo 8-Valve Intercooler Installation

Home85Intercooler in 83Turbo | Before and After | Parts Checklist | Getting Started | Assembly

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Assembly page 8

Arrows show direction to bend tabs.

Install Oil cooler

Clean the inside of the oil cooler using toluene (lacquer thinner). This will remove any built up sludge and increase it's operating efficiency.

The bottom tabs on the oil cooler prevent a clean installation under the right headlight. By bending the tabs down, enough clearance can be achieved to fit it between the radiator support and the inner fender.

Oil cooler installed between the inner fender and radiator support.

 

Bend the bottom tabs down. Fit the oil cooler without the lines attached to facilitate installation. This is a very tight fit. Unclamping the wiring harness and moving it to the side helps.

Determining the exact placement of the oil cooler is up to the individual installer. This author chose a "flat" installation orientation which, while easier and neater, does not promote good airflow through the cooler. Mounting the cooler vertically will allow better airflow through the cooler, but may require trimming of the battery heat shield and other custom fitting work.

Lengthened oil cooler lines in place.

Thread the new oil lines in a path similar to the one seen in the photo.

Loosely fit the oil line connections to the engine and oil cooler. Tighten each one starting with the rightmost engine line.

Replace the oil sensor and attach it's wire.

 

 

Oil cooler in new position.

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Home85Intercooler in 83Turbo | Before and After | Parts Checklist | Getting Started | Assembly