Engine Intake System (Induction) And Turbocharger (2.5L): Intercooler: Installation

Install the intercooler stay RH No. 1, and install the clip (A) which secures the engine wiring harness to the intercooler stay RH No. 1.
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

Fig 1: Locating Intercooler Stay RH Bolts
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Attach the air duct hose to the throttle body.
Tightening torque:

3 N.m (0.3 kgf-m, 2.2 ft-lb)

Fig 2: Locating Air Duct Hose Of Throttle Body
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Set the intercooler to the vehicle, and install the bolts securing the intercooler to the intercooler stay RH No. 1.
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

Fig 3: Locating Intercooler Installation Bolt
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Temporarily tighten the bolt securing the intercooler stay LH to the intake manifold.

Fig 4: Locating Intercooler Stay LH Bolts
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Install the bolts which secure the intercooler to the intercooler stay LH, and install the brake booster vacuum hose to the clip (A).

Fig 5: Locating Brake Booster Vacuum Hose Clip
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Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)
Tighten the bolt securing the intercooler stay LH to the intake manifold.
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

Fig 6: Locating Intake Manifold Bolts
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Tighten the clamp (A) which secures the intake duct to the turbocharger.
Tighten the clamp (B) which secures the air duct hose to the intercooler.
Install the bolts (C) which secures the air bypass valve to the intercooler, and install the air bypass valve.
NOTE: Use a new gasket.

Tightening torque:

T1: 3 N.m (0.3 kgf-m, 2.2 ft-lb)

T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb)

Fig 7: Air Bypass Valve Bolts And Torque Specifications
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Connect the PCV hose (B) to PCV pipe assembly.
NOTE: Make sure that the leak diagnosis connector is connected securely.
Connect the connector (A) to the PCV pipe assembly.

Fig 8: Locating PCV Pipe Assembly Connector
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Connect the PCV hoses (A) and (B) to the PCV pipe assembly.
NOTE: Make sure that the leak diagnosis connector is connected securely.

Fig 9: Locating PCV Hoses Connector
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Install the chamber assembly. <Ref. to INSTALLATION , Chamber Assembly.>