RM3660EC _51 Engine / Hybrid System _080791 NR Series INTAKE / EXHAUST _0392519 INTERCOOLER A

NR Series INTAKE / EXHAUST  INTERCOOLER  INSTALLATION  


PROCEDURE

Hide 17940D 1.INSTALL INTERCOOLER ASSEMBLY

a.
A351379
0.438,0.385 0.365,0.146 0.365,0.146 0.25,0.146 true 0.052,0.073 0.365,0.229 0.313,0.156 10 false *a
*a Protrusion


Install a new throttle body gasket to the intercooler assembly with the protrusion of the throttle body gasket oriented as shown in the illustration.


b.

Temporarily install the intercooler assembly to the air tube assembly with the hose clamp.


c.

Temporarily install the intercooler assembly to the throttle body with motor assembly with the 2 bolts and 2 nuts.


d.

Connect the No. 2 turbo water pipe sub-assembly to the intercooler assembly with the 2 bolts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)


e.

Connect the 2 No. 1 turbo water hoses to the intercooler assembly and slide the 2 clips to secure them.


f.
A394549N01
1.083,1.438 1.24,1.635 0.156,0.198 10 true 4 2.26,1.76 2.542,1.938 0.281,0.177 10 true 1, 5 1.646,0.156 1.792,0.323 0.146,0.167 10 true 2 2.583,0.531 2.729,0.698 0.146,0.167 10 true 3

Tighten the 2 bolts and 2 nuts in the order shown in the illustration.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)


g.

Tighten the hose clamp.

Torque:
6.3 N*m (64 kgf*cm, 56 in.*lbf)


Hide 16554C 2.CONNECT NO. 4 INTERCOOLER COOLING WATER HOSE

a.

Connect the No. 4 intercooler cooling water hose to the intercooler assembly and slide the clip to secure it.

A432244
2.125,0.625 2.583,0.625 true 2.115,0.208 2.354,0.208 2.354,0.208 2.625,0.406 true 2.521,1.146 2.771,1.385 0.25,0.24 10 false *a 2.958,1.948 3.208,2.188 0.25,0.24 10 false *b 2.229,1.396 2.469,1.594 0.24,0.198 10 false *c 1.417,1.385 1.729,1.583 0.313,0.198 10 false *d 1.969,0.542 2.208,0.76 0.24,0.219 10 false *e 1.99,0.135 2.167,0.344 0.177,0.208 10 false *f 2.531,0.917 2.698,1.115 0.167,0.198 10 true *g 2.823,1.396 3.063,1.594 0.24,0.198 10 false *c
*a Up *b Front
*c 60° *d 1 to 5 mm (0.0394 to 0.197 in.)
*e Paint Mark *f Matchmark
*g Paint Mark Area - -


HINT:
·

Position the No. 4 intercooler cooling water hose and clip as shown in the illustration.

·

Push in the No. 4 intercooler cooling water hose until it contacts the stopper.




Hide 16551C 3.CONNECT NO. 1 INTERCOOLER COOLING WATER HOSE

a.

Connect the No. 1 intercooler cooling water hose to the intercooler assembly and slide the clip to secure it.

A432245
2.156,0.625 2.583,0.625 true 2.104,0.219 2.49,0.219 2.49,0.219 2.615,0.406 true 2.521,1.167 2.75,1.365 0.229,0.198 10 false *a 2.938,1.938 3.135,2.135 0.198,0.198 10 false *b 2.229,1.375 2.427,1.552 0.198,0.177 10 false *c 1.406,1.396 1.667,1.594 0.26,0.198 10 false *d 1.99,0.542 2.188,0.75 0.198,0.208 10 false *e 1.979,0.156 2.24,0.344 0.26,0.188 10 false *f 2.531,0.927 2.708,1.135 0.177,0.208 10 true *g 2.813,1.406 3.01,1.583 0.198,0.177 10 false *c
*a Up *b Front
*c 60° *d 1 to 5 mm (0.0394 to 0.197 in.)
*e Paint Mark *f Matchmark
*g Paint Mark Area - -


HINT:
·

Position the No. 1 intercooler cooling water hose and clip as shown in the illustration.

·

Push in the No. 1 intercooler cooling water hose until it contacts the stopper.