INTERCOOLER INSTALLATION

PROCEDURE

1. INSTALL INTERCOOLER ASSEMBLY

   1. Install the intercooler assembly to the fan shroud.

2. INSTALL NO. 1 RADIATOR SUPPORT

   1. Install the No. 1 radiator support to the No. 2 fan shroud and intercooler assembly with the 5 bolts.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

   2. Install the radiator support cushion to the No. 1 radiator support.

3. CONNECT NO. 3 AIR HOSE

   1. 

      *a	View A
      *b	Upper
      *c	RH
      *d	135° (Hose Clamp Bolt Area)
      *e	Stopper
      *f	Paint Mark

      Connect the No. 3 air hose to the intercooler assembly as shown in the illustration.

      Note:

      Before installation, remove any oil residue from the inside of the pipe and hose.

   2. 

      Tighten the hose clamp of the No. 3 air hose on the intercooler assembly side.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Note:

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

      Tip:

      • Push in the No. 3 air hose so that the distance (B) is 0 to 2 mm (0 to 0.0787 in.).

      • Position the hose clamp so that the distance (A) is 4 to 9 mm (0.157 to 0.354 in.).

4. CONNECT NO. 2 AIR HOSE

   1. 

      *a	View A
      *b	Upper
      *c	Front
      *d	300° (Hose Clamp Bolt Area)
      *e	Stopper
      *f	Paint Mark

      Connect the No. 2 air hose to the intercooler assembly as shown in the illustration.

      Note:

      Before installation, remove any oil residue from the inside of the pipe and hose.

   2. 

      Tighten the hose clamp of the No. 2 air hose on the intercooler assembly side.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Note:

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

      Tip:

      • Push in the No. 2 air hose so that the distance (B) is 0 to 2 mm (0 to 0.0787 in.).

      • Position the hose clamp so that the distance (A) is 4 to 9 mm (0.157 to 0.354 in.).

5. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY (except Sedan)

   Click here

6. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for Sedan)

   Click here

7. INSTALL HOOD LOCK ASSEMBLY (for Sedan)

   Click hereClick here

8. CONNECT NO. 1 WATER HOSE CLAMP BRACKET (except Sedan)

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9. CONNECT NO. 1 WATER HOSE CLAMP BRACKET (for Sedan)

   Click here

10. INSTALL BATTERY

    • w/o Glow Plug Controller:

      Click here

    • w/ Glow Plug Controller:

      Click here

11. INSTALL HEADLIGHT ASSEMBLY LH (except Sedan)

    Click here

12. INSTALL HEADLIGHT ASSEMBLY LH (for Sedan)

    Click hereClick here

13. INSTALL HEADLIGHT ASSEMBLY RH

    Tip:

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