REMOVAL AND INSTALLATION


caution
  • Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent.
  • As for the parts cleaner, use the petroleum cleaner whose major component is aliphatic hydrocarbon.
  • Working area should be airy and kept from flame.
Pre-removal and Post-installation Operation
  • Air Cleaner Assembly Removal and Installation (Refer to ).
  • Under Skid Plate and Engine Room Under Cover (Front) Removal and Installation (Refer to GROUP 51 - Under Cover ).
  • Radiator Shroud Cover Removal and Installation (Refer to GROUP 14 - Radiator ).




Removal steps
<<A>>
 >>B<<
 1.
 Intercooler air hose A1
<<A>>
 >>B<<
 2.
 Intercooler air hose B
<<A>>
 >>B<<
 3.
 Intercooler air hose A2
<<B>>
4.
 Power steering return hose clamp and power steering return tube bracket <LHD>
<<C>>
 >>A<<
 5.
 Intercooler assembly


6.
 Deflector plate


7.
 Intercooler air pipe

REMOVAL SERVICE POINTS

<<A>> INTERCOOLER AIR HOSE/AIR PIPE REMOVAL

Make mating marks on the intercooler air hose, intercooler air pipe, and the hose clamp, and remove them.

<<B>> POWER STEERING RETURN HOSE CLAMP AND POWER STEERING RETURN TUBE BRACKET REMOVAL <LHD>
Remove the clamps and brackets of the power steering return hose and tube, and move the power steering return hose and tube to the position where they will not interfere with the intercooler assembly installation and removal.

<<C>> INTERCOOLER ASSEMBLY REMOVAL
1.
caution When moving the stabilizer bar to the position where it will not interfere with the intercooler removal, be careful not to damage the ball joint section of the stabilizer link.
Before removing the intercooler, remove the clamp of the stabilizer bar, and move the stabilizer bar to the position where it will not interfere with the intercooler removal. (Refer to GROUP 33 - Stabilizer Bar ).
2.After removal of the intercooler, return the stabilizer bar to the original position, and install the clamp temporarily.

INSTALLATION SERVICE POINT

>>A<< INTERCOOLER ASSEMBLY INSTALLATION
1.
caution When moving the stabilizer bar to the position where it will not interfere with the intercooler installation, be careful not to damage the ball joint section of the stabilizer link.
Before installing the intercooler, remove the clamp of the stabilizer bar, which was installed temporarily, and move the stabilizer bar to the position where it will not interfere with the intercooler installation.
2.After removal of the intercooler, return the stabilizer bar to the original position, and install the clamp. (Refer to GROUP 33 - Stabilizer Bar ).

>>B<< INTERCOOLER AIR HOSE INSTALLATION



1.Insert hose to stopper end and not overlap with stopper.
2.Place the hose clamp as shown in the figure so that it does not overlap with the bulge and the stopper end. When installing the hose clamp to the intercooler assembly and intercooler air pipe, set the hose clamp 5 ± 1 mm away from the stopper. When installing the hose clamp to the turbocharger assembly or throttle body assembly, set the hose clamp 4 ± 1 mm away from the stopper.

3.
caution Do not use an electric screwdriver or air tool. Manually tighten the hose clamp.
Align the mating marks on the intercooler air hose, intercooler air pipe and the hose clamp. Then, tighten the hose clamp to the specified torque.
Tightening torque: 6.0 ± 1.0 N·m

4.The hose clamp installation angle at the intercooler air pipe side of intercooler air hose A2 is 15°± 15°position.

5.The hose clamp installation angle at the throttle body side of intercooler air hose B is 55° position.