Question about 1995 Subaru Legacy

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Top mount intercooler

I was wondering if there was an easier way of taking out my top mount intercooler. can anyone help me? i need to take that out so i can comfortably get to the starter motor. my arms are too big to reach up to it from underneath the car.

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The easiest wy I have found with mine is to undo all the mounting blots and release all the non fluid hose clamps. you can then manouvre it around with the fluid hoses still connected. It is still a bit of a mission but should only take 20 mins to replace once you have finished. The main problem will be lining up all the intake pipes when putting it back together.

Hope this helps


Posted on Jun 11, 2008


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if you follow the big hose that comes off the left hand side of the intake manifold it leads downward to the side mounted intercooler. The MAP sensor is bolted onto the inner side of the intercooler. You have to unscrew the inner wheel well cover on that side and remove the front fender to get in there to the intercooler area. You can take the front wheel off or turn it full one way to get better access. The intercooler sits on the side of the car and fits between the turbocharger (mounted on the back of the engine) and the intake manifold. I'm sure there's a diy somewhere - probably a DIY for changing boost hoses. Last edited by AgGTI; 10-17-2010 at 04:13 PM.

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You will have to go under the suv to access the two bolts for the starter. You will have to remove the intercooler first then the positeve battery lead. On top of the starter there is another positive lead to the solinoid you will have to do this to then go under the driver side and you will be able to access the starter. You will need a universal extension to do the job easier. Hope this helps

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  • sorry having problem with curser. Will post this and continue in comments window. Hi John, You'll need to rremove the electrical conections to the intercooler and then remove the intercooler ducting before removing the unit from its mounting place. Unbolt the oil feed from top of the turbo and remove all ducting. Remove the bolts from the mounting on the exhaust

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Hope this is helpful, if you need more info get back to me.

1, park car, handbrake on
2, loosen drivers side front wheel bolts,
3, crawl under car use 22mm socket and breaker bar to loosen the crankshaft pulley bolt, it'll probably be quite tight, once undone nip it up again not to tight,
4, open bonnet,
5, jack drivers side of car up, put on axle stand
6, remove wheel
7, loosen and remove intercooler bolts, then intercooler
8, find 6mm allen key
9, behind the starter motor there is a hole in the gearbox housing, put the allen key in it, (may be easier to undo and remove the 3 starter motor bolts)
10, get a 22mm socket put it on the crankshaft pulley bolt, turn the crankshaft bolt clockwise whilst at the same time pushing the allen key into the hole (easier with an assistant but can be done solo) keep turning until the allen key drops into the hole(you'll understand when you do it, may have to turn the engine for quite some time reasonably slowly),
11, thats the engine now on it's timing marks,
12, now put a trolley jack and block of wood under the sump and jack it up until it takes the weight of the engine,
13, remove the left hand side engine mount, basically move the fuel primer to one side, remove the rubber bung if there, then carefully undo the 4 5/8 size bolts and remove the top half of the mount (careful engine doesn't suddenly slip of jack and trap your hand),
14, now remove the 10mm bolts holding the front cambelt cover on, then do the same for the rear cover, except there is one bolt at the back of the cover which is 11mm,
15, now looking at both of the exposed pulleys you will 2 timing holes with a threaded insert behind, on the cam pulley it's at about 4 o clock and i think 2 o clock on the fuel pump, now find the 2 short bolts from the intercooler, they are the right size to fit in the timing holes,
16, now under the arch, remove the crankshaft pulley bolt and pull of the pulley,
17, now remove the lower cambelt cover, all 10mm bolts,
18, now look at the new belt tensioner and you'll see a square hole in it, find the same hole on the car, a short 3/8 socket extension will fit in there and you can then use a ratchet to apply or release the tension,
19, undo but don't remove the two bolts holding the tensioner, now use your ratchet to push the tensioner towards the windowscreen, whilst holding it there use your other hand to release the belt from behind the tensioner,
20, with the belt now loose remove it from round the rest of the components,
21, now replace the waterpump,
22, now replace both the tensioner and idler pulley, to do this you'll need to remove the rest of the metal engine mount, the bolts are quite obvious,
23, replace the belt in the same manner you removed it,
to tension the new belt pull the ratchet towards you then tighten the tensioner bolts at the same time,
24, with the tensioner tightened push the belt in the middle between the two pulleys you should have about half an inch of deflection if correct (check the old belt before removing to give you an idea),
25, now remove the two timing pins in the pulleys and the allen key,
screw the crankshaft pulley bolt into it's hole (leave the pulley off) if you keep screwing it in then the engine will turnover,
26, turn the engine over by hand at least 8 times, then put the timing pins back in as you did at the start, if you've done it all right it'll turn over with no issues
27, recheck the tension again,
28, if alls well then refit the lower cambelt cover,
29, refit the crankshaft pulley,
30, refit everything you've removed, torque all required bolts correctly (except crankshaft pulley which is done last)
31, remove the allen key (2 intercooler bolts will have already been done when fitting the covers and intercooler,
32, turn the engine over again by hand to check there's no rubbing on the cam covers or any other issues,
33, if alls well then top up the engine coolant as you'll have lost alot when doing the waterpump, bleed it properly,
34, put the road wheel back on, lower the car to the ground then torque up the crankshaft pulley bolt,
35, job done start her up then tidy up



Dec 29, 2010 | 1991 Peugeot 405

1 Answer

Im trying to fit a turbo into a 1985 honda civic ok its a stock engine currently but i cleaned it all out and its running smoothly so i though hey why not modify it but im having trouble trying to figure...


1. First you need to find a matched turbo exhasut manifold.
2. Then you can find the position for the turbo once you have fitted the exhaust manifold.
3. You will heed to remove the radiator for now as the mounting position for this may need modifying also.
4. You will then need to get a oil supply line made up and fit this once turbo is fitted.
5. Run all your intercooler and inlet tract piping and your in business.
6. remount your radiator.

That should give you a very quick idea of what needs to be done, of course the job is going to take you longer.

Good Luck


Apr 27, 2010 | 1985 Honda Civic

1 Answer

Help change fan belts on Mitsubishi pajero nm 202 mod can`t undo pully nut is it left or right handed thred

First job is to remove the 4 bolts securing the Intercooler, Its not totaly necessary to remove, but makes it a lot easier to get to the pullies.

Remove the 4 Bolts and move the Intercooler to the left hand side of the engine

Loosen off the locking bolt on the centre of the pully and then loosen the adjuster bolt until belt slackens

Loosen off the forward facing locking bolt and then loosen the adjuster bolt (Hidden behind the top hose) until belt slackens

You should now be able to remove all the belts and replace as required.

On refitting the belts adjust as required and then do up the locking bolts, refit Intercooler and check all connections (you wouldn't like the intercooler fan to fail

Its as easy as that, Good luck and not be held responsible for any 'misfortunes' in carry out the job like breaking out in to a sweat.

Apr 13, 2009 | 2002 Mitsubishi Montero

1 Answer

Top mount intercooler

drain water out first (there is a bung up front on top of front intercooler) the disconnect hoses and undo the 4 bolts holding top intercooler to the engine frame. easy as.

Jun 10, 2008 | 1995 Subaru Legacy

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