In this article we will performing some preventative maintenance to prevent damage to the fins of your intercooler by applying a thin screen over the housing. This is a simple cost efficient DIY that can save you from costly damage in the future.

Skill Level 1 of 5

Time Required <1Hr.

Tools and Equipment

-Intercooler- (Already removed)

-Aluminum Screening

-Cleaning Products

-Silicone

-Straight edge of some type, a tape measure, or yard stick

-Marker or tracing implement



Instructions

-Measure the intercooler about 1" wider for the sides and 2"taller for the heights.

1:Cut out the screen

2:Use the yard stick or suitable device to fold over 1/2", to keep the screen from fraying. Follow this procedure on the remaining three sides.

Note:Do not fold and crease, just enough pressure is required to retain is folded position.



3:Clean the full forward facing surface of the intercooler, top as well as sides.

4:Lay the screen over the intercooler and get it as taught as possible.



5:Remove the screen attempted to retain the newly formed shape. Apply a ~3/8" bead of silicone to the upper and lower edges of the cooler assembly.

6:Reinstall the screen, again being careful to retain it's shape. Pull to adjust.



7:Run your finger along the surface of the screen to spread the bead of silicone and get as much surface contact area as possible.

8:If you would like to decrease any chance of movement in the future. At this point you may add silicone to the sides,I would recommend either near the welds or closer to the intake/outlet sides of the cooler.

Note:Allow the silicone to cure for the time recommended by the manufacturer.

Additional Sleeper Look

-After allowing the silicone to cure, apply black or dark gray appliance paint.



Originally written by Camry