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Should you decide to change the problem EGR cooler on your 54bhp CDI, You’ll need to remove the intercooler. Before you do this I would recommend not bothing and just bypass it instead.
Do You Wish To Continue?
Mad man! Loosen both hose clamps using a 7mm socket.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic1.jpg)
Squash the pipe, push it backwards and remove it. Then loosen the hose clamp next to it.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic2.jpg)
Pull the plastic hose away from the MAF sensor.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic3.jpg)
Remove the rear panels and look at the pipes at the bottom of the intercooler. Undo the hose clamp at each end using a 7mm socket.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic4.jpg)
Pull the hose off of the car.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic5.jpg)
Disconnect the electrical connector from the fan. Lift the tab and pull the connector out.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic6.jpg)
At the top of the fan unit you will see this clip arrangement.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic7.jpg)
You have to:
1 – lever a tab out of the way so…
2 – both tabs can be pressed together.
3 – with the tabs out of the way, pull the fan top towards you to unclip it.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic8.jpg)
With the top unclipped you can lift the fan upwards to disconnect the tabs at the bottom.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic9.jpg)
Go back to the hoses and disconnect the branch pipe.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic10.jpg)
You’ll have to use some pliers to open the clamp whilst you disconnect the pipe.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic11.jpg)
You can then remove the hose clamp to the turbo and remove the main air inlet pipe.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic12.jpg)
Look and the intercooler and you’ll see another pipe. Use the pliers again to open the clamp and disconnect the pipe.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic13.jpg)
Cut both cable ties on the left side of the intercooler.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic14.jpg)
Pull the top of the intercooler towards you and look down the back.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic15.jpg)
Just behind the outlet you’ll see a sensor. Press both tabs and pull the sensor clear.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic16.jpg)
You can now lift the intercooler from the car. In the centre of the intercooler scoop is a deep recess. Remove the fixing.
![](/wp-content/uploads/smartengine/intercooler/451cdi54/fanic17.jpg)
You’ll then be able to pull the scoop out from the car.