Intercooler inspection (4JJ3 with DPD)

1. Intercooler inspection

1) Inspect the intercooler fin for the following.

  • Deformation
  • Collapsing

Note

  • Repair the intercooler fins if deformation or collapsing is found.

Caution

  • If repairing, do not damage the base of the fins.

2) Inspect the inside of the intercooler for dirt.

Note

  • Clean if there is any dirt or foreign material.
  • Clean the inside of the intercooler if it is extremely dirty.

2. Intercooler cleaning

Caution

  • Do not apply high pressure washing to the radiator, intercooler, or peripheral parts while they are installed on the vehicle.

1) Before cleaning, seal the hose connections using caps, cloth tape, etc.

2) Thoroughly wash off fouling that can be removed by washing with tap water.

Note

  • Wet the front and rear surfaces of the intercooler sufficiently.

Caution

  • Do not use a high pressure washing machine or brush.

3) Apply a neutral detergent that contains approximately 8% surface acting agent to the front and rear surfaces of the intercooler fin, and leave for 10 minutes.

Caution

  • Do not use other materials than mild detergent, because using other materials may cause corrosion.

4) Clean the intercooler using a high-pressure washing machine.

Note

  • When dirt is not washed off sufficiently, repeat the cleaning.

Caution

  • High-pressure water should be applied perpendicularly to the intercooler fins from the engine side of the intercooler.
  • High-pressure water should not be taken too close to the fins, or cause them to become deformed.

5) Make sure any dirt on the intercooler fins have been completely washed off.

Note

  • If dirt remains, fine black particles can be seen adhering to the intercooler fins.
  • When dirt is not washed off sufficiently, repeat the cleaning.

6) Wash the intercooler with tap water.

Caution

  • Sufficiently rinse off the detergent ingredient to prevent it from remaining on the core and the resin portions.

7) Remove the seal, and clean the hose connection with tap water.

Caution

  • Thoroughly dry the hose and sensor connections after work.