Intercooler: Service and Repair

Intercooler:

REMOVAL

1. Remove turbocharger air inlet tube from air cleaner and turbocharger (16).
^ Loosen clamps at both ends of air inlet tube.
^ Remove two screws securing tube to air cleaner bracket.
2. Remove bolts (41) retaining duct (42) to the sides and top of the intercooler (43).
3. Raise and suitably support vehicle.
4. Remove bolts (41) retaining duct (42) to the bottom of the intercooler (43).
5. Remove bolts (44) retaining the intercooler (43) to the mounting bracket (45).
6. Remove the mounting bracket (45).
7. Remove bolts (40) retaining the mounting bracket (39) to the front cover.
8. Lower the vehicle.
9. Remove the intercooler inlet tube from the turbocharger (16).
^ Loosen forward hose clamp (47).
^ Pull tube from hose (46).
10. Remove intermediate pipe (36) from the throttle body and the intercooler (43).
^ Loosen rear hose clamp (35) and lower hose clamp (38).
^ Pull intermediate pipe (36) with assembled hoses (34 and 37) and clamps (35 and 38) from throttle body and intercooler.
11. Remove bolts (40) retaining the mounting bracket (39) to the intercooler (43) and generator mounting bracket.
12. Remove intercooler.


INSTALLATION

1. Install intercooler.
2. Install bolts (40) retaining the mounting bracket (39) to the intercooler and generator mounting bracket. Tighten to 20 Nm (15 lb-ft).
3. Connect intermediate pipe (36) to the throttle body and the intercooler.
^ Position intermediate pipe with assembled hoses (34 and 37) and clamps (35 and 38) to throttle body and intercooler.
^ Tighten rear hose clamp (35) and lower hose clamp (38).
4. Connect intercooler inlet tube to the turbocharger.
^ Push tube into hose (46).
^ Tighten forward hose clamp (47).
5. Install bolts (41) retaining duct (42) to the sides and top of the intercooler. Tighten bolts to 1.9 Nm (17 lb-in).
6. Raise and suitably support vehicle.
7. Install bolt (40) retaining mounting bracket (39) to front cover.
8. Install mounting bracket (45).
9. Install bolts (44) retaining the intercooler to mounting bracket (45). Tighten bolts to 20 Nm (15 lb-ft).
10. Install bolts (41) retaining duct (42) to the bottom of the intercooler. Tighten to 1.9 Nm (17 lb-in).
11. Lower the vehicle.
12. Connect turbocharger air inlet tube to air cleaner and turbocharger.
^ Install two screws securing tube to air cleaner bracket.
^ Tighten clamps at both ends of air inlet tube.