INTERCOOLER

TEMPORARILY INSTALL INTERCOOLER ASSEMBLY (for Type A)

Note

If temporary installation is not performed, parts may not be correctly positioned. As a result, connecting parts may not be airtight.

Temporarily install the intercooler assembly to the intercooler support bracket sub-assembly by hand with the 2 bolts in the position shown in the illustration.
Install the 3 gaskets to the intake manifold, intercooler assembly and No. 2 air tube.

Tech Tips

Check that the gasket is securely fitted into the installation groove.
Install the throttle body with motor assembly and No. 2 air tube to the intake manifold with the 4 bolts.

Torque:

10 N*m { 102 kgf*cm, 7 ft.*lbf }
Temporarily install the No. 2 air tube with the 4 bolts, and then tighten them to the specified torque in the order shown in the illustration.

Torque:

10 N*m { 102 kgf*cm, 7 ft.*lbf }
Tighten the 2 bolts of the intercooler assembly.

Torque:

9.3 N*m { 95 kgf*cm, 82 in.*lbf }
Remove the 8 bolts, No. 2 air tube and throttle body with motor assembly.

Note

Do not loosen the installation bolts of the intercooler assembly.
Remove the 3 gaskets from the intake manifold, intercooler assembly and No. 2 air tube.

INSTALL INTERCOOLER ASSEMBLY

Install a new gasket to the intercooler assembly.

Tech Tips

Check that the gasket is securely fitted into the installation groove.
for Type A:

Install the intercooler assembly to the intercooler support bracket sub-assembly with the bolt in the position shown in the illustration.

Torque:

9.3 N*m { 95 kgf*cm, 82 in.*lbf }
for Type B:

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 }
Connect the No. 1 vacuum transmitting hose to the intercooler assembly with the hose clip.

*a	Front of Vehicle
*b	Right Side of Vehicle
*c	2.0 to 7.0 mm (0.0787 to 0.275 in.)
*d	Insert Until Hose Contacts Stopper
*e	Hose Clamp Claw Range
*f	Paint Mark

Connect the No. 8 water by-pass hose and No. 9 water by-pass hose to the intercooler assembly with the 2 clamps.

Tech Tips

Install the water by-pass hoses and hose clamps as shown in the illustration.

INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY (for Type A)

TEMPORARILY TIGHTEN PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for AWD)

INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

INSTALL NO. 1 AIR TUBE

Install the No. 1 air tube to the cylinder head sub-assembly with the 2 bolts.

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Connect the No. 2 air hose to the intercooler assembly and tighten the hose clamp to secure the hose.

Torque:

6.3 N*m { 64 kgf*cm, 56 in.*lbf }
Connect the No. 1 air hose to the intake air resonator and tighten the clamp to secure the hose.

Torque:

6.3 N*m { 64 kgf*cm, 56 in.*lbf }
Connect the No. 3 PCV hose to the cylinder head cover sub-assembly with the hose clamp to secure the hose.
Connect the No. 2 fuel vapor feed hose with the clamp.
Connect the vacuum hose with the clamp.