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Looking inside the intercooler of my '06 MINI Cooper S when I had it off recently, to replace the supercharger, I noticed that the inside was coated in a thin film of oil. This decreases the efficiency of the intercooler by fouling up the heat transfer between the intercooler fins and the air flowing through it.This is the solution I came up with.

Disclaimer: I don't know how your intercooling system works. This How To won't do damage to a first generation MINI Cooper if followed properly but there could be a slight difference in your system that could cause problems. It's unlikely but possible so read the Instructable and then make a decision based on your situation. It is also possible that the inside of your intercooler may never need cleaned. In Gen 1 MINI's the crankcase vents into the air system, which means oil vapor and mist gets into the air system, making a mess of things.

Step 1: Materials and Tools

Materials
  • Acetone, 1 qt,  $7 - Acetone evaporates quickly and is safe for the materials we will be using it on.
  • Rubber Bands,  x 2, Free - Look at the size of the openings on your intercooler and choose your bands accordingly. Heavy duty bands are best.
  • Plastic Bags, x 2, Free - Try to find two without holes.

Tools
  • Gloves - Make sure solvent won't dissolve them or soak through.
  • Mask - Brain cells are good, acetone hates brain cells.
  • Bucket - I used an oil pan already half full of junk coolent. Check all applicable local laws for disposal of used solvents.

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<p>Nice instructable. I would add a few things, if you pardon me:</p><p>When cleaning a well used gasoline tank in my old car (1991 Dodge Spirit R/T Turbo), I used some clean gas first, then plain paint thinner, then acetone, but finished with hot water and liquid detergent. That removed ALL the residues.</p><p>The benefit of finishing with water and detergent, is that you can use a simple hair dryer to completely and quickly dry the item safely and easily! In the case of the gas tank, drying took less than 5 minutes to completely evaporate all the moisture.</p><p>And Don't forget to clean the rubber hoses around the intercooler, as they tend to catch a lot of oily residue too.</p><p>Beware that using compressed air will put some oil back in, unless you use a oil free compressor! Best regards. Amclaussen, Mexico City.</p>

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Bio: Why buy when you can DIY? Educated a Mechanical Engineer and trained as a classical cellist I consider myself a bit of a jack-of-all-trades, dabbling ... More »
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