how long to do an intercooler swap

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lotsofmiles

Father of the Van
Dec 4, 2008
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Michigan
I might have the day off Friday and am thinking about doing the intercooler swap. For the slow to avg paced DIY'er how long is it going to take?

Browsed the instructions this morning and it didn't look too bad.

Just like to know about what to expect.

Got a couple other minor projects to do at the same time - all new lights (headlights, fogs, still need one turn) install the hids, and change the coolant.
 
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jlawles2

Well-known member
Jan 28, 2010
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Danbury, TX
When I did the banks on my truck, I did not have to drain the radiator. Just be careful when removing the upper cross brace and shifting the ac condenser around. You might try the banks website for tech help and read their instructions. IIRC it only took me about 2 - 3 hrs for the intercooler install. The whole kit bumper to bumper took me 18 hrs with 4 hrs on the exhaust manifold b/c I kept rotating the three hole gasket one turn when trying to install it.
 
Car RamRod

Car RamRod

Right Meow!
Apr 12, 2009
231
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Just west of Mobile, AL
Two hours is about right. Pull the grille, lights, light brackets (two of those bolts are Torx AKA star) remove the hood latch, then the trans cooler, it has two bolts and two plastic clips. Unplug the air temp sensor. Now, to remove the top of the core support and front bracket together, you need to pull a bunch of bolts. Four bolts across the bottom of the front bracket (two on each side) Three bolts on each end of the top (right behind where the headlight mounts, bolts point up) two bolts for the A/c condenser top mounts. One bolt for the windshield washer fluid reservoir. four bolts across the top of the fan shroud (two hold the TCM mount) all those are 10mm, the last two hold the CAC on and are 13mm. at this point, the top bar and front mount can be pulled off together. I take a cardboard box and slide it over the condenser to protect it, then I pick it up and put it on top of the engine. Loosen the inter cooler duct clamps (11mm deep well) and pull the boots off the inter cooler. Now unbolt the radiator from the inter cooler and remove the inter cooler. Reverse steps to reassemble, box up old inter cooler, test drive truck to UPS store and send old inter cooler to me, since I need one, go back home and have a beer or six....
 
RENODMAX

RENODMAX

Dead Wrong
Mar 4, 2008
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Two hours. I didn't drain the radiator I put a ppe in. Just pulled the stuff off the top
 
66FLH

66FLH

Been to Hell and back!
Jul 23, 2008
39
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Northern New Mexico
Took me about two hours on my Chevy and that includes drinking beer and chasing my stupid German Shepards around the yard cause' they kept stealing stuff off my work bench!
 
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lotsofmiles

Father of the Van
Dec 4, 2008
3,097
0
0
Michigan
JD4440 said:
Are you just draining the radiator James or pulling the block plugs also ?
Click to expand...
I was planning on pulling lower hose, measure what I get and note color, fill with water, run +bring upto temp, drain again, and decide if I want to repeat the drain refill again. Unless someone tells me that's stupid :)

Multi-quote didn't work or I hit the wrong button.
 
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lotsofmiles

Father of the Van
Dec 4, 2008
3,097
0
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Michigan
About 2 hours sounds great. Thanks for the replys. I'll leave the lab at home she likes to help too.


What about cutting the airbox mount? The banks instrucions say it has to be chopped and give a diagram.
 
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lotsofmiles

Father of the Van
Dec 4, 2008
3,097
0
0
Michigan
Quick question if anyone knows...


Instructions say to reinstall radiator to intercOoler with 5/16 - 18 by 1 1/8 long bolt supplied in the banks system (instruction 31 page 22 part # 96786 v.3.0 I downloaded off banks site)

I didn't get any bolts, is that the same as the stockers I pulled out. First one is going in kinda snug and I don't want to strip anything
 
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lotsofmiles

Father of the Van
Dec 4, 2008
3,097
0
0
Michigan
got it in and mostly back together:happy2:

lower pass side rad to intercooler bolt was the biggest pain to line up. other than that went fine
 
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lotsofmiles

Father of the Van
Dec 4, 2008
3,097
0
0
Michigan
didnt run it yet. got everything back in and together except the headlight mounts, lights and grille. had about 387,495,684 messages from the wife asking when I was coming home, and when I got beer I only had $4 on me so I ran out of beer fast. theres another $18 somewhere in the van or building but I cant find it. bought the wife a coffee earlier and had $22 left:confused:

So tomorrow I'll install the HID's and change the coolant. Then the test drive:D
 
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lotsofmiles

Father of the Van
Dec 4, 2008
3,097
0
0
Michigan
oh, I did see one small spot on the tube that goes from the intercooler up to the intake. Looked like a mix of water/oil. about the size of 2 of these : :) could be from the h20/meth mixing with the oil. didnt look big enough to be concerned with after over 100K spraying.
 
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