INTERCOOLER INSTALLATION

PROCEDURE


  1. INSTALL NO. 9 WATER BY-PASS HOSE


    1. A01MYKSC01
      *a View A
      *b RH
      *c Front

      Install the No. 9 water by-pass hose to the intercooler assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  2. INSTALL NO. 8 WATER BY-PASS HOSE


    1. A01MXZJC01
      *a View A
      *b RH
      *c Front

      Install the No. 8 water by-pass hose to the intercooler assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

    2. Install the intercooler assembly to the vehicle.

  3. SET INTERCOOLER ASSEMBLY


    1. Set the intercooler assembly to the engine assembly.

  4. INSTALL INTAKE MANIFOLD


    1. Install 2 new intake manifold gaskets to the intake manifold.

    2. Temporarily install the intake manifold to the cylinder head sub-assembly and cylinder block sub-assembly with the 4 bolts and 2 nuts.

    3. A01MZ1GC03
      B003WAF Bolt
      B003U82 Nut

      Tighten the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  5. CONNECT INLET HEATER WATER HOSE B

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  6. CONNECT VACUUM TRANSMITTING HOSE ASSEMBLY

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  7. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

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  8. CONNECT NO. 3 WATER BY-PASS HOSE

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  9. CONNECT ENGINE WIRE

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  10. CONNECT OUTLET HEATER WATER HOSE A

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  11. CONNECT INLET HEATER WATER HOSE A

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  12. INSTALL NO. 2 WATER BY-PASS PIPE

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  13. INSTALL NO. 2 VENTILATION HOSE

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  14. INSTALL AIR CLEANER HOSE ASSEMBLY

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  15. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  16. INSTALL INTERCOOLER RESERVE TANK ASSEMBLY

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  17. INSTALL PURGE VALVE (PURGE VSV)


  18. INSTALL INTERCOOLER ASSEMBLY


    1. Install the intercooler assembly to the intercooler support bracket sub-assembly with the 3 bolts.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

  19. CONNECT NO. 1 AIR TUBE


    1. Connect the No. 1 air tube to the intercooler assembly and tighten the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  20. CONNECT ENGINE WIRE


    1. Connect the engine wire with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Engage the 2 clamps.

  21. INSTALL HEATER WATER PUMP ASSEMBLY


    1. Install the heater water pump assembly to the heater water pump bracket with the 2 bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  22. CONNECT NO. 9 WATER BY-PASS HOSE


    1. A01MY4ZC01
      *a View A
      *b Rear
      *c Lower

      Connect the No. 9 water by-pass hose to the water by-pass pipe and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  23. CONNECT NO. 8 WATER BY-PASS HOSE


    1. A01MV55C01
      *a View A
      *b Upper
      *c RH

      Connect the No. 8 water by-pass hose to the No. 2 water by-pass pipe and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  24. CONNECT NO. 1 VACUUM TRANSMITTING HOSE


    1. A01MY16C01
      *a 2 to 5 mm (0.0787 to 0.197 in.)

      Connect the No. 1 vacuum transmitting hose assembly to the intercooler assembly and slide the clip to secure it as shown in the illustration.

  25. CONNECT NO. 2 TURBO WATER HOSE


    1. A01MXURC01
      *a View A
      *b Front
      *c RH

      Connect the No. 2 turbo water hose to the water by-pass pipe and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  26. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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