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.
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.
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.
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:
The whole intercooler unit should then lift away.
Refitting is simply the reverse of what we’ve just done.