I thought my installation of an intercooler in my 83 244GL was going well until I got to the bottom bracket of the oil cooler. I did successfully get the top bracket off and the specially designed-for-intercooler use top bracket installed. The lower bracket on the cooler is then supposed to be removed and rotated 180 degrees, (see Angel Morales article on 240 intercooler installation: http://www.geocities.com/MotorCity/Speedway/2204/int.htm) in order to provide the needed space for the new intercooler/radiator sandwich. Well, even after spraying, (more like RAINING), big quantities of P'Blaster on the lower bolts and threaded "barrels" of the cooler which hold the lower bracket on - I 'thought' I was getting the bolts to turn. Oh yes, they were turning all right, the apparently aluminum barrel-shaped "nuts" right along with them. I would like to reuse this cooler - but now am afraid that the thing may be ruined. Are these barrel-shaped captive nuts on the cooler made out of aluminum? I would say the bolts have badly seized to them. Ideas anybody?
Thanks, Grayrider in intercooler limbo land.

Hi,
I ran into the same kind of thing when I installed my intercooler on my 82.
I eyed up the area and the only difference there seemed to be by not rotating the bracket was interference from the radiator at the lower oil hose. Since I knew the bolts seemed doomed, I just left it alone and put a piece of
rubber hose on the lower oil cooler hose where it rubbed against the radiator. I
also bent the side shield so air could not escape between the cooler and the radiator. That was all I seemed to be able to do. It's been fine now for about
5 years. Hope this helps you.

Dave 82 242ti 272k mi.

Thank you Dave for your good tip. I will see if I can't make my setup work in the same manner without all the *&@!%# mess with those seized up lower bracket bolts. Glad to hear that you already have some life out of your setup.

Randy 83 244T (not an "I" yet)