Intercooler: Service and Repair

Intake Air, Intercooler Piping And Components:

REMOVAL, AIR INTAKE HOSES

Air Piping Alignment:

1. Remove all vacuum/pressure source hoses.
2. Remove the air bypass hose.
3. Disconnect air intake hose A at the clamps to hose C, B and at the air flow sensor connection.
4. Remove the air intake hose A along with the air bypass valve.
5. Disconnect the clamp and remove air intake hose B from the forward turbocharger inlet.
6. Disconnect the clamp and remove air intake hose C from the rear turbocharger inlet.

REMOVAL, RIGHT INTERCOOLER AND AIR PIPES (FORWARD TURBOCHARGER)

Right Intercooler Piping, Alignment Points:

1. Remove air hose C.
2. Remove air hose D.
3. Remove the right side intercooler air duct.
4. Remove the right intercooler.

REMOVAL, LEFT INTERCOOLER AND AIR PIPES (REAR TURBOCHARGER)

Left Intercooler Piping, Alignment Points:

1. Disconnect and remove air hose G.
2. Remove the mounting bolts and remove air pipe A.
3. Disconnect and remove air hose B.
4. Disconnect and remove air hose E.
5. Remove the mounting bolts and remove air pipe B.
6. Remove the mounting bolts and remove air pipe C.
7. Disconnect and remove air hose F.
8. Remove the engine oil cooler from its mountings.
9. Remove the left intercooler air duct.
10. Remove the left intercooler.

INSPECTION
1. Check the intercooler fins and tubes for punctures, bends or clogging by foreign matter.
2. Inspect the air hoses and air pipes for cracks, brittleness or punctures.

CAUTION: Be careful not to allow any dirt or other foreign objects to enter the hoses, pipes or intercooler.

INSTALLATION
Install in the reverse order of disassembly.

Torque, intercooler to body: 12 - 15 Nm (9 - 11 ft.lbs.)
Torque, air pipe bolts: 12 - 15 Nm (9 - 11 ft.lbs.)
Torque, air hose clamps: 4 Nm (3 ft.lbs.)

Left Intercooler Piping, Alignment Points:

Right Intercooler Piping, Alignment Points:

NOTE: Pay special attention to the alignment marks (indicated by the arrows in the appropriate image) on the hoses and pipes to obtain a proper fit during assembly.