Citroen DS3 Intercooler Installation
Instructions
Tools Required
T20 Torx
10mm socket and matching ratchet
Flat headed Screwdriver
Trim button removal tool
Hose clamp driver
13mm socket and matching ratchet
1. Open the bonnet and remove the four T20 torx’s running along the top of the bumper.
2. Remove the T20 torx and then pull the arch lining out enough to undo the 10mm bolt.
3. Under the car, using a 10mm socket and ratchet undo the two 10mm bolts holding the
bumper to the cowling.
4. Using a T20 Torx and 10mm socket and ratchet undo the three T20 bolts and the one 10mm
bolt shown below to release the arch lining from the bumper. Repeat on both sides of the
car.
5. Grab the sides of the bumper as seen below and pull outwards unclipping it from the wings.
Do this on both sides.
6. You can now remove the bumper but just before you pull it all the way off you will need to
disconnect the appropriate wiring going to the fogs lights and daylight running lights.
7. Using a 10mm socket and ratchet undo the two 10mm bolts holding the light in place then
remove the plug on the back of the light with a screwdriver to lift the tap upwards and pull
the plug away from the light unit. Repeat on both sides of the car.
8. Remove the cold air feed using a trim button removal tool to lift the tab upwards.
9. Using a ratchet and 10mm socket, undo the 10mm bolt to remove the bracket on the aircon
pipe. Also unclip the other aircon pipe from its holder.
10. Unclip the intercooler fan connector by pressing down on the clip and pull apart.
11. With a flat headed screwdriver (or something similar) push the 2 tabs in on the intercooler
bracket to release it from its cowling.
12. Undo the 2 boost pipes connected to the intercooler with a hose clamp driver and remove
the pipes.
13. Now lift up and pull towards you on the cowling to remove the standard intercooler. Make
sure you don’t damage the water pipe goin to the expansion tank in the process.
14. Now attach the two 45 degree silicon hoses to each hard pipe using jubilee clips.
15. Attach the two aluminium hose joiners to the 45 degree silicon pipes previously fitted fitting
the shorter one on the right and the longer one on the left and tighten jubilee clips and
attach the other two 45 degree silicon bends to the other end.
16. With a 13mm socket undo and remove the two lower 13mm bolts on the crash bar.
17. Place the intercooler in place and fit the 2 silicon hoses to the intercooler and tighten. It is
easier to do while the intercooler isn’t bolted up.
18. Using the two 13mm bolts you previously removed from crash bar, replace them holding
the intercooler in place.
19. Now the intercooler is secure pull up the plastic lip under the intercooler so it touches the
bottom intercooler brackets and mark the hole through the brackets. Using a 7mm drill bit
drill a hole in the plastic where you marked it.
20. Using the M6x12, 2x M6 washer and M6 nyloc nut, bolt both sides of the intercooler to the
lower plastic lip.
21. Now refit everything using stages 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 and 14 in reverse.
Instalation is now complete.
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