INTERCOOLER INSTALLATION

CAUTION / NOTICE / HINT

Note

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE


  1. INSTALL INTAKE AIR SURGE TANK ASSEMBLY WITH INTERCOOLER


    1. Install a new gasket to the intake air surge tank assembly with intercooler.

      Tech Tips

      Check that the gasket is securely fitted into the groove on the installation area.

    2. B006CBTC02
      B006AHR Intake Air Surge Tank Assembly with Intercooler Installation Bolt
      B006EC9 Do not Tighten the Non-removable Bolt.

      Install the intake air surge tank assembly with intercooler with the 8 bolts in the order shown in the illustration.

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

      Note

      Do not tighten the non-removable bolt.

    3. Connect the No. 1 PCV hose to the intake air surge tank assembly with intercooler, and slide the clip to secure the hose.

    4. Install the 2 bolts.

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

  2. INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET


    1. Install the No. 2 intercooler support bracket with the bolt and nut to the intake air surge tank assembly with intercooler and cylinder head cover sub-assembly LH.

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

  3. INSTALL INTERCOOLER SUPPORT BRACKET


    1. Install the intercooler support bracket with the bolt and nut to the intake air surge tank assembly with intercooler and cylinder head cover sub-assembly RH.

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

  4. INSTALL NO. 2 SURGE TANK STAY


    1. Install the No. 2 surge tank stay with the 2 bolts to the intake air surge tank assembly with intercooler and No. 2 timing chain cover assembly.

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

  5. INSTALL NO. 1 SURGE TANK STAY


    1. Install the No. 1 surge tank stay with the 2 bolts to the intake air surge tank assembly with intercooler and No. 2 timing chain cover assembly.

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

  6. INSTALL E.F.I. VACUUM SENSOR ASSEMBLY

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  7. INSTALL NO. 3 TURBO PRESSURE SENSOR

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  8. INSTALL NO. 8 FUEL VAPOR FEED HOSE


    1. Install the No. 8 fuel vapor feed hose to the intake air surge tank assembly with intercooler and fuel vapor feed pipe sub-assembly, and slide the clips to secure the hose.

  9. INSTALL NO. 9 FUEL VAPOR FEED HOSE


    1. Install the No. 9 fuel vapor feed hose to the intake air surge tank assembly with intercooler and fuel vapor feed pipe sub-assembly, and slide the clips to secure the hose.

  10. INSTALL NO. 10 ENGINE WIRE


    1. Connect the connectors, attach the clamps to connect the No. 10 engine wire from the intake air surge tank assembly with intercooler.

  11. INSTALL NO. 9 ENGINE WIRE


    1. Connect the connectors, attach the clamps to connect the No. 9 engine wire from the intake air surge tank assembly with intercooler.

  12. INSTALL SURGE TANK COVER


    1. Install the surge tank cover to the intake air surge tank assembly with intercooler.

  13. INSTALL NO. 1 WATER BY-PASS TUBE

    Note

    Do not bend the No. 1 water by-pass tube when removing it.


    1. Temporarily install the No. 1 water by-pass tube with the 6 bolts to the intake air surge tank assembly with intercooler.

    2. B006EK0

      Tighten the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B006EIT

      Tighten the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. B006DIG

      Tighten the bolt.

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

    5. for Bank 1:


      1. B0069O9C01
        B006DHE Connect the No. 1 Water By-pass Pipe
        B006B42 Insert the Retainer in the Direction of the Arrow Shown in the Illustration.

        Connect the No. 1 water by-pass pipe to the intake air surge tank assembly with intercooler and slide the retainer to secure it as shown in the illustration.

        Note


        • Push in the retainer until a click sound is heard.

        • Pull on the No. 1 water by-pass pipe to confirm that the hose is securely connected.

        • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.

    6. for Bank 2:


      1. B006FN3C01
        B006DHE Connect the No. 1 Water By-pass Pipe
        B006B42 Insert the Retainer in the Direction of the Arrow Shown in the Illustration.

        Connect the No. 1 water by-pass pipe to the intake air surge tank assembly with intercooler and slide the retainer to secure it as shown in the illustration.

        Note


        • Push in the retainer until a click sound is heard.

        • Pull on the No. 1 water by-pass pipe to confirm that the hose is securely connected.

        • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.

    7. B006B8YC01
      *a Paint Mark (yellow)
      *b Paint Mark (white)

      Connect the No. 1 turbo water hose and No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the clips to secure the hose.

      Note

      Be sure to correctly connect the No. 1 turbo water hose and No. 2 turbo water hose. Incorrect installation may damage the turbocharger sub-assembly.

      Tech Tips

      Make sure the paint mark on the pipe side and the paint mark on the hose side are the same color.

    8. B006EVRC01
      *a Paint Mark (yellow)
      *b Paint Mark (white)

      Connect the No. 3 turbo water hose and No. 4 turbo water hose to the No. 2 turbo water pipe sub-assembly, and slide the clips to secure the hose.

      Note

      Be sure to correctly connect the No. 3 turbo water hose and No. 4 turbo water hose. Incorrect installation may damage the turbocharger sub-assembly.

      Tech Tips

      Make sure the paint mark on the pipe side and the paint mark on the hose side are the same color.

    9. Connect the No. 1 water by-pass hose to the No. 1 water by-pass tube, and slide the clip to secure the hose.

    10. B006DCQC01
      *a Intercooler Outlet Pipe
      *b Intercooler Inlet Pipe
      *c Clip Installation Range 120°
      *d Front Side
      *f Vehicle Left Side
      *g Paint Mark (blue)
      *h Paint Mark (yellow)

      Connect the intercooler cooling water inlet hose and intercooler cooling water outlet hose, and slide the clips to secure the hose to the No. 1 water by-pass tube.

      Note

      Make sure the hose clips and paint marks is oriented as shown in the illustration.

  14. CONNECT OUTLET HEATER WATER HOSE

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  15. CONNECT INLET HEATER WATER HOSE

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  16. CONNECT ENGINE WIRE HARNESS


    1. for Bank 1:


      1. B006FLH

        Connect the connectors and attach the clamps to connect the engine wire harness.

      2. Install the 4 bolts.

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

    2. Engine Front Side:


      1. B006FVT

        Connect the connectors and attach the clamps to connect the engine wire harness.

      2. Install the 2 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      3. B006A3R

        Connect the connectors and attach the clamps to connect the engine wire harness.

      4. Install the bolt.

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

    3. for Bank 2:


      1. B006CVZ

        Connect the connectors to connect the engine wire harness.

      2. Install the 2 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      3. B006CPH

        Connect the connectors and attach the clamps to connect the engine wire harness.

      4. Install the bolt.

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

  17. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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  18. INSTALL V-BANK COVER BRACKET


    1. Install the No. 1 V-bank cover bracket and No. 2 V-bank cover bracket with the 4 bolts to the intake air surge tank assembly with intercooler.

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

  19. INSTALL FUEL VAPOR FEED PIPE


    1. Install the fuel vapor feed pipe with the 2 bolts to the intake air surge tank assembly with intercooler.

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

  20. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  21. ADD COOLANT (for Intercooler)

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  22. INSPECT FOR COOLANT LEAK (for Intercooler)

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