INTERCOOLER REMOVAL

PROCEDURE


  1. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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  2. DISCONNECT NO. 2 TURBO WATER HOSE


    1. A01R6CB

      Slide the clip and disconnect the No. 2 turbo water hose from the water by-pass pipe.

  3. DISCONNECT NO. 1 VACUUM TRANSMITTING HOSE


    1. A01R7D1

      Slide the clip and disconnect the No. 1 vacuum transmitting hose from the intercooler assembly.

  4. DISCONNECT NO. 8 WATER BY-PASS HOSE


    1. A01R69B

      Slide the clip and disconnect the No. 8 water by-pass hose from the No. 2 water by-pass pipe.

  5. DISCONNECT NO. 9 WATER BY-PASS HOSE


    1. A01R54V

      Slide the clip and disconnect the No. 9 water by-pass hose from the water by-pass pipe.

  6. SEPARATE HEATER WATER PUMP ASSEMBLY


    1. A01R6SV

      Remove the 2 bolts and separate the heater water pump assembly from the heater water pump bracket.

  7. DISCONNECT ENGINE WIRE


    1. A01R5AC

      Disengage the 2 clamps.

    2. Remove the bolt to disconnect the engine wire.

  8. DISCONNECT NO. 1 AIR TUBE


    1. A01R4UW

      Loosen the hose clamp and disconnect the No. 1 air tube from the intercooler assembly.

  9. DISCONNECT INTERCOOLER ASSEMBLY


    1. A01R4BH

      Remove the 3 bolts and disconnect the intercooler assembly from the intercooler support bracket sub-assembly.

  10. REMOVE PURGE VALVE (PURGE VSV)


  11. REMOVE INTERCOOLER RESERVE TANK ASSEMBLY

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  12. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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  13. REMOVE AIR CLEANER HOSE ASSEMBLY

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  14. REMOVE FUEL HOSE BRACKET

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  15. REMOVE NO. 2 VENTILATION HOSE

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  16. REMOVE NO. 2 WATER BY-PASS PIPE

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  17. DISCONNECT INLET HEATER WATER HOSE A

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  18. DISCONNECT OUTLET HEATER WATER HOSE A

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  19. DISCONNECT ENGINE WIRE

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  20. DISCONNECT NO. 3 WATER BY-PASS HOSE

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  21. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

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  22. DISCONNECT VACUUM TRANSMITTING HOSE ASSEMBLY

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  23. DISCONNECT INLET HEATER WATER HOSE B

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  24. REMOVE INTAKE MANIFOLD


    1. A01R5WMC01
      B0073AQ Bolt
      B0077IM Nut

      Remove the 4 bolts, 2 nuts and intake manifold from the cylinder head sub-assembly.

    2. Remove the 2 intake manifold gaskets from the intake manifold.

  25. REMOVE INTERCOOLER ASSEMBLY


    1. Remove the intercooler assembly from the engine assembly.

  26. REMOVE NO. 8 WATER BY-PASS HOSE


    1. A01R7LR

      Slide the clip and remove the No. 8 water by-pass hose from the intercooler assembly.

  27. REMOVE NO. 9 WATER BY-PASS HOSE


    1. A01R55I

      Slide the clip and remove the No. 9 water by-pass hose from the intercooler assembly.