Intercooler removal (4JJ3 with DPD)

1. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.

3) Raise the vehicle.

2. Inner liner removal

1) Remove the inner liner from the front fender panel.

3. Front bumper removal

1) Remove the intake air duct from the air cleaner box and radiator core support.

Legend

  1. Intake air duct
  2. Clip

2) Remove the soft nose from the front bumper support.

3) Remove the front bumper support from vehicle.

Legend

  1. Clip
  2. Screw
  3. Soft nose
  4. Front bumper support

4) Remove the front bumper from the vehicle.

Legend

  1. Front bumper
  2. Clip

5) Disconnect the connector from the front bumper.

4. Intercooler preparation

1) Prepare a shop cloth for the lower part of the drain plug.

2) Remove the drain plug from the intercooler and drain the engine oil to a pan.

3) Install the drain plug to the intercooler.

Caution

  • Check that the engine oil is discharged.

Tightening torque: 1.2 N・m { 0.12 kgf・m / 10.6 lb・in }

Legend

  1. Intercooler
  2. Drain plug

5. Charge air cooler temperature sensor 1 removal

1) Disconnect the connector from charge air cooler temperature sensor 1.

2) Remove charge air cooler temperature sensor 1 from the intercooler.

Legend

  1. Charge air cooler temperature sensor 1
  2. Intercooler

6. Front bumper impact bar removal

1) Remove the air guide from the front bumper impact support.

Legend

  1. Air guide

2) Remove the front bumper impact bar from the frame.

Legend

  1. Front bumper impact bar

3) Remove the support bracket from the frame.

Legend

  1. Support bracket

4) Remove the air guide from the radiator lower support.

Legend

  1. Air guide

7. Front bumper impact support removal

1) Remove the headlight fixing bolt from the front bumper impact support.

2) Remove the front bumper impact support from the vehicle.

Legend

  1. Front bumper impact support

3) Remove the front end engine hood stay from the frame.

Legend

  1. front end engine hood stay

8. Intercooler removal

1) Disconnect the air intake hose from the intercooler.

2) Disconnect the intake hose from the intercooler.

Legend

  1. Air intake hose
  2. Clamp
  3. Intercooler
  4. Clamp
  5. Intake hose

3) Remove the intercooler from the frame.

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