Removing the Pajero Intercooler

Pajero For Sale

Removing the intercooler from the Pajero is the first step in many jobs under the bonnet as it takes up so much room. As such I thought it would be good to post a write-up about how to perform this task on its own. This might look tricky to a novice (it did to me) but it’s really very easy and should take no more than a few mintues.

First of all look at the left hand side of the reversed L-shape unit and identify the 2 big black hoses coming off it. I detached these two hoses’ jubilee clips with a small socket at the points shown below. These were the easiest clips to get to. Once untightened they should pull off easily.

Pajero Intercooler Hoses

Secondly look at the right hand side of the intercooler where you’ll see 2 electrical clips bundled closely together (see arrows below). Take the 2 clips apart.

Pajero Intercooler Electrical Clips

Thirdly we need to remove the 2 bolts that hold the intercooler in place at the rear of the engine bay. But, before you do this you may also need to unbolt a small bracket that holds tubes that is held onto the rear mounting of the intercooler. I’m not sure if this is the case for all Pajeros as it looks as though it may have been bracketed there at a later stage.

So, in the picture below, take off the bracket in the middle first and let it dangle out of the way. Then remove the 2 bolts that hold the bracket of the intercooler in place.

Pajero Intercooler Rear Mounts

Then all that remains is to remove the 2 bolts at the front of the intercooler where they fix to the front of the engine bay:

Pajero Intercooler Front Mounts

The whole intercooler unit should then lift away.

Pajero Intercooler Removed

Refitting is simply the reverse of what we’ve just done.

19 Comments on Removing the Pajero Intercooler

  1. When you disconnect the electrical conectors, do note that they have a securing clip – they need to be sqeezed in the right place before pulling them apart. As usual with electrical conectors do not pull apart by the wires!

    It took me a while to work out how to squeeze the bigger one and ended up using a small screwdriver to lever the lock out of the way…

  2. Hello, Can you tell me how to find out if your turbo is working?
    2. Also I have an aerial stuck down that wont come up, how do I get to it to fix it?

    Sincerely Jenn

  3. Hi Jenn
    You’d know about it if the trubo wasn’t working as you’ve have almost no acceleration and a cloud of smoke behind you.
    You’ll need a new ariel from a Mitsubishi supplier. I’ll let you know how to fit it once you’ve got one!!!

  4. Mike Billig // July 27, 2010 at 4:39 pm // Reply

    Hi Tim, so close yet so far, i have had the miss fortune, to have had a refurbished head fitted to my 2.8 TDI inter-cooler (4M40) like the one in your pictures. unfortunately i believe, the connections for the vacuum (4 little valves fitted to the inter-cooler bracket) and the electrical connections have been re-connected incorrectly, please could you tell me where to get a schematic of these connections or explain the correct configuration? Also the vacuum pipes on the inlet side are doubtful.HELP!

    • I have the same question, where does the small vacuum hose connects to, the upper mount or lower mount?

  5. 4th picture down, removing the bolt left hand side/front, looks ok, how do you put the nut back on when putting it back?. I can’t see how to get into the space where the rad is located? thanks

    • Ages since I’ve taken that off Simon so I can’t really remember. I don’t remember any problems at all with it though, so I’m assuming mine has a nut welded in place that you bolt into.

    • Habari Simon,
      I write you from Kenya, where I just fitted a 4M40 from a Delica in a ’96 Pajero. I can’t recommend this to anyone since it looks as if only the block and head are similar, all the rest is different and has to be transferred.
      I ended up with a messy bunch of vacuum pipes and can’t work out which one goes where anymore.
      Also the electrical wiring was ‘modified’ by Kenyan ‘mechanics’ and is in a terrible mess. I spend many hours on the internet to source a vacuum diagram, but to no avail. Can you help, or should I start looking for a similar vehicle -that has not yet been subjected to an African mechanic- to find out the connections?
      Please assist if you can.
      Kind Regards,
      Rico van den Hurck.

  6. Tim cheers, will let you know how I get on. Simon

  7. instructions for this made the job quite easy, thanks

  8. nicely done Tim!

  9. When You Remove The Intercooler there won’t be any device to cool the turbo

    • I wouldn’t advise running the engine without it! As stated at the top, these instructions are just to allow you to get at other engine parts underneath.

  10. simon dainty // December 28, 2011 at 4:21 pm // Reply

    hi tim i have a lwb 92 2.5 auto do you know where i could find a new or used intercooler as im really struggling

  11. When does the turbo intercooler fan operate?Thanks.

  12. Gill Coleman // January 11, 2016 at 2:34 pm // Reply

    Hi, can you help my hubby, can u give us a description of where the thermostat is as we have removed the top hose and there’s no sign of the thermostat in the housing, jusdt a hole.
    Thank you

  13. Gill Coleman // January 11, 2016 at 2:39 pm // Reply

    Can u give us a description the of where the thermostat is as we have removed the top hose and there is no sign of the thermostat in the housing just a hole.

  14. Thermostat location is by oil filter housing. Just follow bottom rad hose

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