Intercooler¶

Components¶

Removal of intercooler¶

1. Disconnect cable from negative terminal of battery.

   Caution

   Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery.

2. Remove engine under covers.

3. Remove RH engine hood side panel.
4. Remove No.1 air intake connector.

5. Remove No.2 air intake connector.

   

6. Remove cruise control actuator (w/ cruise control system) and accelerator linkage. (See Cylinder block (3S-GTE) › Removal of engine, step 13)

7. Remove engine compartment cooling fan. (See steps 4 and 5 on page CO-34)
8. Disconnect engine wire clamps from mount bolts of No.2 timing belt cover. (See step 12 (a) on page FI-111)
9. Remove RH front engine hanger. (See Cylinder head (3S-GTE) › Removal of cylinder head, step 11)

10. Disconnect parking brake cable from body.

    Remove the three clamp bolts, and disconnect the parking brake cable.

    

11. Remove lower suspension brace.

    Remove the two bolts and suspension brace.

    

12. Remove idler pulley bracket and A/C compressor.

    1. Remove the clamp nut, and disconnect the A/C hoses.

       

    2. Loosen the idler pulley nut and adjusting bolt, and remove the drive belt.

       

    3. Disconnect the A/C compressor connector.

       

    4. Remove the bolt and connector clamp of the A/C compressor.

    5. Remove the three bolts and idler pulley bracket.

    6. Remove the two bolts, and disconnect the A/C compressor from the engine.

       

       Hint

       Suspend the compressor to the strut rod with a string.

       

13. Remove intercooler.

    Remove the three bolts and intercooler.

    

14. Remove cool air inlet.

    Remove the three bolts and air inlet.

    

Installation of intercooler¶

(See Intercooler)

1. Install cool air inlet.

   Install the air inlet with the three bolts.

   

2. Install intercooler.

   Install the intercooler with the three bolts.

   

3. Install A/C compressor and idler pulley bracket.

   1. Temporarily install the A/C compressor with the two bolts.

      

   2. Install the idler pulley bracket with three bolts.

      Torque:

      • A – 275 kg-cm (20 ft-lb, 27 N·m)
      • B – 375 kg-cm (27 ft-lb, 37 N·m)
      • C – 250 kg-cm (18 ft-lb, 25 N·m)

      

   3. Install the connector clamp of the A/C compressor with the bolt.

   4. Connect the A/C compressor connector.

   5. Tighten the two bolts of the lower side holding the A/C compressor to the cylinder block.

      Torque: 250 kg-cm (18 ft-lb, 25 N·m)

      

   6. Install the drive belt with the idler pulley nut and adjusting bolt.

      

   7. Install the A/C hoses with the nut.

      

4. Install lower suspension brace.

   Install the suspension brace with two bolts.

   Torque: 740 kg-cm (54 ft-lb, 73 N·m)

   

5. Install parking brake cable.

   Install the parking brake cable with the two clamps and three bolts.

   

6. Install RH front engine hanger. (See Cylinder head (3S-GTE) › Installation of cylinder head, step 31)

7. Install engine wire clamps to mount bolts of No.2 timing belt cover. (See step 5 (b) on page FI-118)
8. Install engine compartment cooling fan. (See steps 1 and 2 on page CO-36)
9. Install cruise control actuator (w/ cruise control system) and accelerator linkage. (See Cylinder block (3S-GTE) › Installation of engine, step 36)
10. Install No.1 air intake connector.

11. Install No.2 air intake connector.

    

12. Connect cable to negative terminal of battery.

13. Adjust A/C drive belt.

    Drive belt tension:

    • New belt – 160 ± 25 lb
    • Used belt – 100 ± 20 lb

14. Install RH engine hood side panel.

15. Install engine under covers.