My car never came with the black plastic intercooler cover, but after acquiring one the long bolts that go into the top of the intercooler don't want to tighten down. One on the right side tightens a little bit, then becomes incredibly tight as if it got crossthreaded. The other one doesn't even want to stay in, it just slides out - can't even get it in down to the bottom all the way.

Any suggestions? Should I not even bother trying to put the intercooler cover back on or is there a way to fix the threads. Referring to #6 in the diagram.

 

Yes you buy the brackets that the bolts go into

you may have to remove the intercooler to see / remove the brackets...but that’s easy

 

We actually offer the intercooler cover bolts in stainless more affordable than the OEM ones.
https://www.waymotorworks.com/stainl...-cooper-s.html

 

I’m pretty sure I have the brackets (toward the rear of the engine), it’s just the damn bolts don’t catch the threads. Maybe spraying some WD40 in there and going at it with a wire brush will help.

 

Check your intercooler orientation. You may have to remove the intercooler to verify; However; on the back edge/furthest edge of the intercooler (towards the windshield). the two holes (left & right) where the bolts go into, should be smooth shafts going straight down, to accommodate the long Torx 30, M6x60mm(?) bolts.
The two front most bolt holes (left & right) will be threaded to accommodate the shorter Torx bolts.
If you remove the intercooler, you will notice that the two smooth bolt shafts/sleeves will have a black plastic retaining clip that holds the hex shaft in place. Make sure both smooth shafts are at the back edge (left & right) of the intercooler. If not, they are easy to remove and swap them from front to back or left to right...

Sorry for any confusion to my reply. I can be rather pedantic.

Addendum: Yes - as you have stated above; It looks like there maybe an issue with the short #4 (back) mounts. Perhaps they are stripped.... or missing(?)....
Hope you've figured it out.

 

This is good info, luckily I figured it out. The bracket threads were just very corroded as the intercooler cover hadn't been on when I bought the car (who knows how long it was off), worked the bolts into the rear bracket in and out gently with some WD40 till they finally caught the threads and all is good.

 

That's awesome!
Glad the hear the brackets were there and just needed a little persuading.
(Almost) nothing worse than having to hunt around part stores for small bits and pieces.