Ianh wrote:

A fair bit of swearing..but it’s part of a bigger job, my intercooler has split so I’ve purchased a BAS intercooler plus BAS silicon intercooler hoses. Then on inspection I noticed a very small leak on my radiator, so I purchased a gen LR radiator taken off a delivery mileage 2015 Puma when it had an v8 engine swap from new.

The fun stated yesterday, a cold Saturday morning on my drive.
1Soft A Bar off
2.Aircon grill off
3.Top fan shroud Off
4.Slam panel off, insufficient exposed threads to get right hand studs out using two nut method so needed mole grips to get them out. Good that BAS includes replacement bolts ( better for next time )
5.Viscous fan off, using BAS tool to hold fan pulley, glad I bought that tool as it was very tight, used long breaker bar to hold tool plus draper single ended open 36mm spanner and slipped 2 ft of jack handle over it to provide leverage. It’s normal counter clockwise to undo, but I did need to double check as I had to apply a fair bit of torque to loosen it.
6.Drained coolant. No fuel cooler on mine so no coolant pipes to drain from on near side chassis rail so had to drain by removing pipe from oil cooler thermostat. Due to location it means you can’t get all into a single bucket so lots of strategically placed containers to catch as much as possible. When drained I hosed all the chassis, in the chassis and all under the truck to wash away residue.
7. Intercooler hoses detached from intercooler
8. Top nearside radiator hose detached, plus small pipe from coolant tank.
9. Bottom fan shroud removed.
10. Left and right brackets removed, prop bonnet with long wood pole going to ground in engine bay where bottom shroud used to be.
11. Lift radiator off bottom mounts and move slightly more into engine bay. This gives room to remove intercooler.
12. Lift intercooler out, nearside first.
13. Detach lower offside radiator pipe then small one on the bottom front of radiator.
14 catch coolant in bucket.
15 remove radiator and wash down area to remove coolant residue.
16 remove nearside intercooler pipe from metal intercooler pipe.
17 remove turbo to intercooler pipe. Remove nut on bracket that holds pipe away from engine and steering parts then bend back bracket.
18 remove intercooler pipe from turbo and manipulate pipe out.
19. Fit new silicon hose. And reattach bracket, make sure pipe is not rubbed by steering parts. BAS states 15 -20mm needs cutting off at turbo end on RHD models, after several tries , cutting a bit more off each time, I found 20mm was correct to avoid steering column rubbing, leaving a 10mm gap, but I do have the bracket to keep it clear.
20. Remove top bolt on metal intercooler pipe bracket.
21. Loosen pipe clip on hose to inlet manifold.

And that’s where I’m at now, so a fair bit of colourful language already, and more to come I expect.