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GReddy Intercooler Installation
(continued)
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Next, remove the cover to the
pulley wheels where the throttle cable is terminated:
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With the cover removed, you'll see
that three cables converge on a tri-level pulley wheel:
The cable from the throttle pedal is (naturally) the bottommost cable. It
needs to be removed to get it out of the way.
I always choose to loosen the
lock nut with the most available threads showing, and leave the other one
in place. That lets me loosen the cable fully without needing to readjust
the amount of slack later.
Once the cable is removed, you
can push it behind the turbo for now.
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The brake booster line also needs
to be removed. This is the line running along the top of the engine
compartment just above the stock intercooler piping:
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Loosen the hose clamp at the
bulkhead (firewall) fitting...
...and also at the intake manifold:
The line is clamped to the body with several 10mm nuts. Once they have
been removed, you can set it aside. Make sure you cover the ends to
prevent dirt from getting into the system, and tape over the exposed
openings.
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Now comes the tough part. My goal was to remove the stock intercooler
without ruining it in the process. Unfortunately, Toyota engineers decided
to integrate a bracket into the right engine mount, such that it stands
ready to puncture the IC without hesitation:
This bracket poses a danger to the IC core, so work around it carefully if
you are trying to save the stock IC.
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Remove the 12mm bolt attaching the upper IC mount:
Now remove the two 10mm bolts that fasten the bracket to the intercooler.
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There are two 12mm lower bolts to remove:
Remove these, but be careful, as the IC might want to slip out of its
saddle when the last one is removed.
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