INTERCOOLER REMOVAL

PROCEDURE

1. REMOVE HEADLIGHT ASSEMBLY LH (except Sedan)

   Click here

2. REMOVE HEADLIGHT ASSEMBLY LH (for Sedan)

   Click here

3. REMOVE HEADLIGHT ASSEMBLY RH

   Tech Tips

   Use the same procedures for the RH side and LH side.

4. REMOVE BATTERY

   
   

   • w/o Glow Plug Controller:

     Click here

   • w/ Glow Plug Controller:

     Click here

5. DISCONNECT NO. 1 WATER HOSE CLAMP BRACKET (except Sedan)

   Click here

6. DISCONNECT NO. 1 WATER HOSE CLAMP BRACKET (for Sedan)

   Click here

7. REMOVE HOOD LOCK ASSEMBLY (for Sedan)

   
   

   • for LHD:

     Click here

   • for RHD:

     Click here

8. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY (except Sedan)

   Click here

9. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for Sedan)

   Click here

10. DISCONNECT NO. 2 AIR HOSE

    
    

    1. 

       Loosen the hose clamp and disconnect the No. 2 air hose from the intercooler assembly.

11. DISCONNECT NO. 3 AIR HOSE

    
    

    1. 

       Loosen the hose clamp and disconnect the No. 3 air hose from the intercooler assembly.

12. REMOVE NO. 1 RADIATOR SUPPORT

    
    

    1. Remove the radiator support cushion from the No. 1 radiator support.

    2. 

       Remove the 5 bolts and No. 1 radiator support from the No. 2 fan shroud and intercooler assembly.

13. REMOVE INTERCOOLER ASSEMBLY

    
    

    1. 

       Remove the intercooler assembly from the fan shroud.