The steps below are shortened from the Vauxhall TIS pages for the Speedster. The VX220 shares the same engines and most of the car, but check anything unusual against your own car. The TIS pictures and the full wording aren't reproduced, so use the workshop manual if you are doing the job. We haven't seen owners' accounts of this job, so there are no owner tips here.
For the charge cooler upgrade see Pro Alloy charge cooler: fitting to a Turbo.
Intercooler
Turbo (Z20LET) only.
Remove
- Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
- Remove air intake hose from intercooler (Release clip; Remove, then discard cable tie)
- Lower vehicle to suitable working height
- Remove rear road wheel from right side
- Use special socket located under front bonnet
- Remove 4x wheel bolt
- Remove right rear wheel arch liner (Remove 4x screw, 2x clip)
- Remove insulation pad from wheel arch (Pull off)
- Release side pod from wheel arch (Remove, then discard 2x nut)
- Remove side pod from vehicle (Remove 2x screw)
- Remove air deflector from intercooler and body (Remove 6x clip)
- Remove intercooler hose from intercooler (Release clip)
- Disconnect harness connector from charge pressure sensor (Release integral clip)
- Remove intercooler from support bracket and chassis (Remove, then discard nut; Remove 2x bolt)
- Remove intercooler from vehicle Note: Intercooler shown removed from vehicle for clarity.
- Release support bracket for purge valve and charcoal canister
- Remove 3x bolt
- Position to one side
- Remove charge pressure sensor from intercooler (Remove bolt; Remove, then discard seal)
Install
- Install charge pressure sensor to new intercooler (Install bolt; Use new seal)
- Install intercooler to vehicle
- Install support bracket for purge valve and charcoal canister
- Install 3x bolt
- Install intercooler to support bracket and chassis (Install new nut; Install 2x bolt)
- Connect harness connector to charge pressure sensor (Secure integral clip)
- Install intercooler hose to intercooler (Secure clip)
- Install air deflector to intercooler and body (Install 6x clip)
- Install side pod to vehicle (Install 2x screw)
- Secure side pod to wheel arch (Install 2x new nut)
- Install insulation pad to wheel arch
- Install liner to wheel arch (Install 4x screw, 2x clip)
- Install rear road wheel to right side (Install 4x bolt, security bolt; Do not tighten)
- Raise vehicle
- Intercooler air intake hose to intercooler (Secure clip; Install new cable tie)
- Install engine undertray (Install 13x bolt, 13x washer)
- Lower vehicle
- Secure rear road wheel right side (Tighten 4x bolt, security bolt 90)
Hose, turbocharger to intercooler
Turbo (Z20LET) only.
Remove
- Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
- Remove hose from turbocharger and intercooler (Release 2x clip; Remove, then discard cable tie)
Install
- Install new hose to turbocharger and intercooler (Install new cable tie; Secure 2x clip)
- Install engine undertray (Install 13x bolt, 13x washer)
- Lower vehicle
Hose, intercooler to throttle body
Turbo (Z20LET) only.
Remove
- Disconnect intercooler hose from connecting pipe for throttle body (Release clip; Pull off)
- Raise vehicle to suitable working height
- Remove rear road wheel from right side
- Use special socket located under front bonnet
- Remove 4x wheel bolt
- Remove right rear wheel arch liner (Remove 4x screw, 2x clip)
- Remove intercooler hose from intercooler (Release clip; Remove, then discard 4x cable tie)
Install
- Install new intercooler hose to intercooler (Secure clip; Install 4x new cable tie)
- Install liner to wheel arch (Install 4x screw, 2x clip)
- Install rear road wheel to right side (Install 4x bolt, security bolt; Do not tighten)
- Lower vehicle
- Secure rear road wheel right side (Tighten 4x bolt, security bolt 90)
- Install intercooler hose to throttle body (Secure clip)
Charge pressure sensor
Turbo (Z20LET) only.
Remove
- Release rear road wheel from right side
- Use special socket located under front bonnet
- Release 4x wheel bolt
- Raise vehicle
- Remove rear road wheel from right side (Remove 4x bolt, security bolt)
- Remove wheel arch liner from right side (Remove 4x screw, 2x clip)
- Disconnect harness connector from charge pressure sensor (Release integral clip)
- Remove charge pressure sensor from intercooler (Remove bolt, washer)
Install
- Install charge pressure sensor to intercooler (Install bolt, washer)
- Connect harness connector to charge pressure sensor (Secure integral clip)
- Install wheel arch liner to right side (Install 4x screw, 2x clip)
- Install rear road wheel to right side (Install 4x bolt, security bolt; Do not tighten)
- Lower vehicle
- Secure rear road wheel to right side (Tighten 4x bolt, security bolt 90)