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   talon7.org     +                                   |        talon7.org
   ===============|        INTERCOOLER CLEANING       |==================
                  |             03/20/03              |
                  |            paranoidxe             | 
                  +=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=+ 

  Before we even begin to start into this document, you must make sure that
  you have PLENTY of time for the intercooler to dry after cleaning it.

//--                                                                 --\\
 Applies to: 1st/2nd Gen Turbo DSMs (90-98)                              
 
 Reasoning: Granted your vehicle is fairly old, grime accumulates on the 
 innercooler, causing loss of cooling power. The cooler the air, the     
 better it is for the turbo..by cleaning the intercooler it will perform 
 close to peak again.                                                   
                                                                           
   Supplies Needed:                                                         
   Socket Wrench                                                            
   10mm and 12mm sockets                                                    
   Philips & Flathead Screwdriver                                           
   Alcohol (recommended) or Gasoline
   Jack 

The amount of cleaner needed depends on how dirty it is, I bought 4 pints
of 91% Isopol Alcohol, and 2 quarts of 70% Ispol Alcohol and that did the
trick for me. My IC was on a scale of 1 to 10 about a 6 in terms of dirty.

                                       
//--                                                                 --\\
 


                     = = =  THE PROCESS  = = =

Note: you might want to remove the wheel if you need to, it may make it a
little easier, I've managed to remove the intercooler without having to
remove the front tire.

   1) Remove the splash shield thats in front of the passanger tire.
   2) Jack the front of the car up, Remove hosing that is attached to the
      intercooler.
   3) Remove the intercooler bolts with a 12mm socket, 2 are located near
      the bottom of the intercooler. Then there is one dead center on top
      of the intercooler which may be difficult to remove.
   4) Remove the intercooler.
   5) Remove any leafs, bugs, dirt, etc. from the outside. BE VERY CAREFUL
      as the fins are very sensitive. If you can, try straightening any of
      the bent fins you might come acrossed.
   6) Now comes the cleaning part, you can use a plastic bag and elastics to
      seal off the pipes on both sides..or you can just use your hands..your
      call.
   7) Pour the alcohol or gas into one of the pipes until the fluid almost
      comes out the same side as you are pouring it into. 
   8) Cover up both sides, shake for about 5 minutes...pour out and repeat
      cleaning process. If extremely dirty, repeat a 3rd time.
   9) Put the intercooler back on the same way you took it off, if you wish
      you can leave the splash shield off which will allow for better 
      intercooler airflow.