To remove the intercooler, first disconnect the cable from the negative battery terminal. Lift each side of the engine cover off the ball studs and remove it from the vehicle. Disconnect the PCV tubes from the valve covers and oil tank, moving them out of the way. Raise the vehicle and support it securely on jackstands, then place a drain pan under the intercooler and loosen the radiator drain plug. Locate the quick-connect fittings for the intercooler hoses, using a bent-tip screwdriver or pick to pull on the retaining rings and separate the hoses from the fittings. Disconnect the electrical connectors from the supercharger air inlet and outlet pressure sensors, the Intake Air Temperature sensor, and the barometric pressure sensor. Remove the intercooler cover bolts in reverse order of tightening, noting that access to the rear bolts may require lowering the front subframe. Remove the cover and gasket, then take off the intercooler insulator from the supercharger, covering the opening to prevent dirt from entering. Do not reuse the intercooler cover gaskets. Remove the intercooler outlet fasteners and slide the outlet out from the cover and cooler. Turn the intercooler cover upside down, remove the mounting bolts, and take the cooler off the cover, replacing the outlet-to-cooler O-rings with new ones. For installation, ensure the mating surfaces of the intercooler cover and supercharger are clean, then install the intercooler with new O-rings and tighten the bolts to the specified torque. Attach the intercooler outlet to the intercooler fittings, ensuring the O-rings are not damaged, and tighten the outlet-to-cover bolts. Remove any covering from the supercharger opening and install the gasket, followed by a new intercooler cover gasket. Install the intercooler cover and bolts, tightening them in sequence to the specified torque, and then install and tighten the intercooler radiator drain plug. Refill and bleed the intercooler system, and complete the installation by cleaning any spilled coolant, starting the engine to check for proper operation and coolant leaks, and reinstalling the engine covers.
