Vauxhall Vectra 1.9 CDTI Intercooler installation
T25 Male Torx drive
Flat head screwdriver / Hose clamp driver
3/8 Long extension bar
3/8 female E14 Torx drive
Body panel clip removal tool
5mm Allen key
1/ Using a body panel clip removal tool remove the two clips from the top of the bumper.
2/ Remove the two T25 Torx screws in each of the front wheel arches.
3/ Remove the three plastic body panel clips from the lower section of the bumper that
connects it to the underneath of the car.
4/ Remove the three T25 Torx from each of the lower arch liners.
5/ Disconnect the wiring harness for the front bumper you may need to pull the bumper
out slightly to access this.
6/ Completely remove the front bumper and place in a safe place.
7/ Remove the six female E14 Torx from the front crash bar and remove the crash bar.
8/ Remove the air-conditioning radiator securing T25 Torx screws.
9/ Remove the Intercooler hoses by undoing the hose clamps and pulling the hoses off of
10/ Using the 10mm spanner and the T25 Torx bit remove the intercooler support bracket
screws this can be tricky due to the limited space. There is one on each side of the
11/ Slide the air conditioning radiator up off of its brackets and move enough so that you
can pull the old intercooler out.
12/ Place the forge intercooler back into its place and use the supplied 5mm Allen head
13/ fit the intercooler hoses back onto the new intercooler.
14/ Refit the Air conditioning radiator, crash bar and bumper check that all of the hose
clamps are tight and test drive the vehicle.
Thank you for buying Forge Motorsport products.
As always, with any questions or concerns about this product, please feel free to contact your local or
preferred Forge Motorsport dealer/installer, or you may contact us directly.
Forge Motorsport UK (+ 44) 1 452 380 999 / [email protected]
Forge Motorsport US (407) 447-5363 / [email protected]