Polaris XP Turbo/S & Pro XP Racing Intercooler Core Replacement

Remove the rear bed with a T-40 Torx

Remove the rear valance if the vehicle still has OEM exhaust. Then remove exhaust, O2 sensor and heat shield. Circled is the intercooler. (See figure 1).

Located on the intercooler are two brackets. Remove all (3) plugs from the brackets using a flat blade screwdriver.

Label both coolant lines feeding into the intercooler (top/bottom), pinch both lines off to stop coolant from leaking out, place a catch can underneath the machine and disconnect the lines from the intercooler.

Remove (2) 10mm bolts and spacers holding the fuel rail in place. (See figure 2).

Loosen both V-Clamps retaining the intake manifold to the engine, 11mm socket. (See figure 2).

Remove the charge tube going into the throttle body using a 11mm socket and remove (4) 10mm bolts on the throttle body going to the intake. (See figure 3)

Remove the top bolt on the transmission bracket, holding the plenum using a 13mm socket. (See figure 4).

Remove both intake manifolds from the engine, allowing the plenum and intercooler to rotate.

Take out (10) 8mm bolts on the intercooler (2) of them will have brackets on them. Remember where they are located. Now the intercooler can be removed, and able to pass the frame.

Take the gasket off the OEM intercooler and place it on a work bench. Next you will cut the gasket and reinstall just the bottom portion onto the new intercooler. (See figure 5-7).

Reinstall the new intercooler. Place both brackets into their original position and fasten all (10) 8mm bolts down to 7 ft lbs. Reconnect the (2) throttle body and (1) 02 sensor back to the correct bracket. (See figure 8).

Reinstall the plenum to transmission 13mm bolt. Do not fasten down yet.

Reassemble both V-Clamps onto the intake and engine. Make sure they are seated before you fasten down.

Reassemble the throttle body to the plenum using (4) 10mm bolts. Reinstall the charge tube at this time using a 11mm socket.

Reassemble the fuel rail bolts and spacers. Torque to 7ft lbs. You can now fasten the plenum-transmission bolt down.

Re-connect both top/bottom coolant hoses into their original orientation. Undo clamps.

Reassemble the rear heat shield and exhaust. Connect the 02 sensor back into the exhaust.

Top the coolant off and let the engine run for 10min or until coolant level is correct.

Reassemble the box and rear valance.