Intercooler: Service and Repair

REMOVAL:

1. Drain the engine coolant.
2. Disconnect the condenser fan connector and the radiator hoses.
3. Disconnect the coolant reservoir hose.
4. On A/T models, remove the A/T cooler hoses from the radiator and place a pan under the radiator to catch any fluid that leaks out.
5. Remove radiator supports and remove the radiator.
6. Remove the No.4 air cleaner pipe with No.1 and No.2 air cleaner hoses.

Removing Air Cleaner Pipe:

7. Remove the No.1 air cleaner pipe from the turbocharger and Intercooler by removing the clamps for No.5 and No.6 air cleaner hoses.

Removing No.1 Air Cleaner Pipe:

8. Remove the mounting bolts for the Intercooler.

Intercooler:

9. Lift the Intercooler from the engine compartment.

INSTALLATION:

1. Lower the Intercooler into the engine compartment.
2. Install mounting bolts and tighten.
3. Install the No.1 air cleaner pipe to the turbocharger and Intercooler with No.5 and No.6 air cleaner hoses.
4. Install the No.4 air cleaner pipe with No.1 and No.2 air cleaner hoses.
5. Lower the radiator into the engine compartment and attach with the radiator supports.
6. On A/T models, reconnect the cooler hoses.
7. Reconnect the coolant reservoir hose.
8. Reconnect the radiator hoses and condenser fan connector.
9. Fill engine with coolant.
10. Start the engine and check for leaks.