Intercooler: Service and Repair

Intercooler

REMOVAL

1. Remove the collector cover.
2. Remove the clamp (A) which holds the intake duct to the intercooler, and remove bolts which secure the intercooler to the intercooler stay LH.






3. Loosen the clamp (A) securing the intake duct to the intercooler, and remove the bolt securing the intercooler to the intercooler stay RH to remove the intercooler.






4. Remove the brake booster vacuum hose from the clip (A), and remove the intercooler stay RH and intercooler stay LH.






5. Remove the V-belts.
6. Remove the generator.
7. Remove the power steering pump.
1. Remove the suction hose from intake duct.






2. Disconnect the connector (A) from power steering pump, and remove the power steering pump together with the power steering pump bracket from engine and stopper rod.






3. Mount the power steering pump together with the power steering pump bracket on RH side wheel apron.

8. Remove the radiator sub fan motor assembly.
9. Remove the engine coolant hose from the clip (A).
10. Remove the bolts which secure the intake duct to the turbocharger, and remove the air by-pass valve from the intake duct.






11. Remove the intake duct from intake manifold.






INSTALLATION

1. Install the intake duct to the intake manifold.






2. Attach the engine coolant hose to the clip (A).
3. Install the air by-pass valve to the intake duct, and install the bolts which secure the intake duct to the turbocharger.

NOTE:
- Use new O-rings.
- Be careful not to pinch the O-ring.

Tightening torque:
T1: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb)






4. Install the radiator sub fan motor assembly.
5. Install the power steering pump.
1. Install the power steering pump together with the power steering pump bracket to engine and stopper rod, and connect the connector (A) to the power steering pump.






2. Install the suction hose to the intake duct.






6. Install the generator.
7. Install the V-belts.
8. Install the intercooler stay RH and intercooler stay LH, and install the brake booster vacuum hose to the clip (A).

Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb






9. Place the intercooler and attach the bolt to secure the intercooler to the intercooler stay RH. And tighten the clamp to secure the intake duct to the intercooler.

Tightening torque:
T1: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb)






10. Install the bolts which secure the intercooler to the intercooler stay LH, and tighten the clamp which holds the intake duct to the intercooler.

Tightening torque:
T1: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb)






11. Install the collector cover.