REMOVAL AND INSTALLATION <4N1, 4D5>


<4N1>


caution
  • Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent.
  • As for the parts cleaner, use the petroleum cleaner whose major component is aliphatic hydrocarbon.
  • Working area should be airy and kept from flame.
  • Do not use an electric screwdriver or air tool. Manually tighten the hose clamp.
Pre-removal Operation
  • Air Intake Hose Removal.

 Post-installation Operation
  • Air Intake Hose Installation.




Removal steps

>>C<<
 1.
 Air hose A

>>C<<
 2.
 Air hose B


·
 Front bumper assembly


3.
 Intercooler assembly

>>C<<
 4.
 Air pipe A


5.
 O-ring

>>C<<
 6.
 Air pipe B


7.
 O-ring


8.
 Intercooler bracket A <M/T>


9.
 Intercooler bracket B

<4D5>


caution
  • Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent.
  • As for the parts cleaner, use the petroleum cleaner whose major component is aliphatic hydrocarbon.
  • Working area should be airy and kept from flame.
  • Do not use an electric screwdriver or air tool. Manually tighten the hose clamp.
Pre-removal Operation
  • Air Intake Hose and Air Duct Removal (Refer to ).

 Post-installation Operation
  • Air Intake Hose and Air Duct Installation (Refer to ).




Removal steps

>>A<<
 1.
 Air hose A1

>>A<<
 2.
 Air hose B2


·
 Front bumper reinforcement


3.
 Intercooler pipe and intercooler assembly

>>A<<
 4.
 Intercooler pipe

>>B<<
 5.
 Intercooler gasket


6.
 Intercooler assembly

>>A<<
 7.
 Air hose B1

>>A<<
 8.
 Air pipe B1


9.
 Intercooler bracket

INSTALLATION SERVICE POINTS

>>A<< AIR PIPE/AIR HOSE/INTERCOOLER PIPE INSTALLATION
1.If the oil adheres to the insertion area of the pipe or the hose, degrease it.
2.


Install the air hose to the air pipe or the intercooler pipe with the matching marks aligned as shown in the figure.
3.When installing the air hose to the throttle body or the turbocharger, install the air hose with its matching mark located as shown in the figure.




4.Insert air hose to stopper end and not overlap with stopper.
5.Place the hose clamp as shown in the figure so that it does not overlap with the bulge and the stopper end. When installing the hose clamp to the air pipe or intercooler assembly, set the hose clamp 5 ± 1 mm away from the stopper end. When installing the hose clamp to the throttle body or turbocharger, set the hose clamp 4 ± 1 mm away from the stopper end.

>>B<< INTERCOOLER GASKET INSTALLATION

Install the intercooler gasket as its protrusion is in the direction shown.

>>C<< AIR PIPE/AIR HOSE INSTALLATION
1.If the oil adheres to the insertion area of the pipe or the hose, degrease it.
2.

Install the air hose to the air pipe with the matching marks aligned as shown in the figure.
3.When installing the air hose to the throttle body or the turbocharger, install the air hose with its matching mark located as shown in the figure.

4.Insert air hose to stopper end and not overlap with stopper.
5.Place the hose clamp as shown in the figure so that it does not overlap with the bulge and the stopper end. When installing the hose clamp to the pipe, set the hose clamp 5 ± 1 mm away from the stopper end.