13517704

Removal and Installation

Remove the engine cover.

Remove the engine room under cover.

(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")

Drain the coolant.

(Refer to Cooling System - "Coolant")

Remove the air duct.

(Refer to Intake and Exhaust System - "Air Cleaner")

Remove the battery.

(Refer to Engine Electrical System - "Battery")

Remove the air cleaner assembly.

(Refer to Intake and Exhaust System - "Air Cleaner")

Remove the battery tray.

(Refer to Engine Electrical System - "Battery")

Remove the intercooler inlet pipe & hose (A).

Tightening torque

Clamps :

4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)

(If equipped with a cap, tighten it until the cap is removed.)

Bolt :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

note

Align the marks of the intercooler pipes/hoses and assembling parts.

Remove the intercooler outlet pipe & hose (A).

Tightening torque :

4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)

(If equipped with a cap, tighten it until the cap is removed.)

note

Align the marks of the intercooler pipes/hoses and assembling parts.

10.

Disconnect the radiator lower hose (A).

11.

Disconnect the radiator upper hose (A).

12.

Disconnect the wire harness connectors around the EGR & thermostat housing and detach the wiring protector (A) after unfastening the mounting bolts.

13.

Disconnect the heater hoses (A), turbocharger water hoses (B) and EGR cooler hose (C).

14.

Remove the intake manifold.

(Refer to Intake And Exhaust System - "Intake Manifold")

15.

Remove the high pressure EGR cooler. (Euro 4/5 only)

(Refer to Intake And Exhaust System - "High Pressure EGR cooler")

Remove the adapter EGR pipe. (Euro 2/3 only)

Tightening torque :

19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)

16.

Disconnect the oil cooler hoses (A).

17.

Remove the water pump and pipe.

(Refer to Cooling System - "Water Pump")

18.

Remove the EGR & thermostat housing assembly (A).

Tightening torque :

19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft)

19.

Install in the reverse order of removal.

20.

Fill the radiator with coolant.

(Refer to Cooling System - "Coolant")

21.

Start engine and check for leaks.