VP D6 Intercooler advice

[Ribliam]

I have stripped the Intercooler unit off my engine to clean and try to fix a slight leak, the service manual says to use a plastic faced mallet to remove the insert from the intercooler by striking after removing the end caps, has anyone any experience of having done this as I don't want to hit it to hard as to cause damage..

 

[Andyroonot]

I've done a couple of these, and depending on their age & the amount of build up in the element, you'll either need a very big plastic hammer, or, as I used, a large hammer & a big lump of wood - the wood is better because as the element gets knocked down the housing, you won't be able to hit the end with a hammer at all! You'll also need a secure work bench to hook the air hose over the edge of, to prevent the housing moving too much. And another person to hold the housing down while you hit it, at the same time as keeping the end of the wood in the middle of the element to knock it out square...but apart from that it's pretty easy!

We also take our elements to a local radiator specialist to be cleaned of any build up in the holes - new o-rings to reseal and your done!

 

[aquatom]

In med waters these leak every year. The the rear end cap of the heat exchanger also leaks but is more dificult to see. If not kept under control the water leaks onto the startermotor and costs you loads to repair.