Charge Air Cooler Cooling Tube Replacement

Charge Air Cooler Cooling Tube Replacement

Removal Procedure

Important: The charge air cooling tubes are replaced as a set. If any one of the charge air cooler cooling tubes needs to be replaced, all the charge air cooler cooling tubes must be replaced in order to maintain consistent cooling of the charge air.




1. Drain the charge air cooling system.
2. Remove the front section of the supercharger inlet duct assembly.

Important: Do not allow any draining coolant to contact the supercharger drive belt.

3. Place a shop rag under the front portion of the supercharger to collect any remaining coolant that may drain from the charge air cooling system.
4. Remove the charge air cooler front manifold, gasket, O-rings, and spacers.




5. Remove the charge air cooler rear manifold, gaskets, O-rings, and spacers.




6. Carefully remove the outboard charge air cooler cooling tubes.
7. The charge air cooler cooling tubes are fragile and must be placed in a protected area.




8. Carefully remove the inboard charge air cooler cooling tubes.
9. The charge air cooler cooling tubes are fragile and must be placed in a protected area.




10. Inspect the charge air cooler cooling tubes for the following:
^ Damaged, clogged, bent or missing fins (1)
^ Damage, corrosion or restrictions to the cooling passages (2)
^ Damage, corrosion, restrictions or missing diversion end plate (3)




11. Inspect the charge air cooler cooling tubes for the following:
^ Damaged, clogged, bent or missing fins (1)
^ Damage, corrosion or restrictions to the cooling passages (2)
^ Damage, corrosion or restrictions to the intake end (3)

Important: The charge air cooling tubes are replaced as a set. If any one of the charge air cooler cooling tubes needs to be replaced, all the charge air cooler cooling tubes must be replaced in order to maintain consistent cooling of the charge air.

12. Replace any damaged, corroded or restricted charge air cooler cooling tubes as a set.

Installation Procedure




1. Carefully install the inboard charge air cooler cooling tubes.




2. The charge air cooler cooling inboard tubes are installed with the restrictor plates (1) to the front of the supercharger, towards the drive belt pulley.




3. Align the wide notch at a 45 degree angle up from horizontal and outboard as shown.




4. Carefully install the outboard charge air cooler cooling tubes.




5. The charge air cooler cooling outboard tubes are installed with the restrictor plates (1) to the rear of the supercharger. The open end of the cooling tube will be to the front of the supercharger, towards the drive belt pulley.




6. Align the wide notch at a 45 degree angle up from horizontal and outboard as shown.




7. Install the charge air cooler cooling tube rear spacers.




8. Install the NEW charge air cooler cooling tube rear O-rings.




9. Install the NEW charge air cooler rear manifold gaskets.




10. Install the charge air cooler rear manifold.





Notice: Refer to Fastener Notice.

11. Install the charge air cooler rear manifold bolts.

Tighten the charge air cooler rear manifold bolt to 10 N.m (89 lb in).




12. Install the charge air cooler cooling tube front spacers.




13. Install the NEW charge air cooler cooling tube front O-rings.




14. Install the NEW charge air cooler front manifold gasket.




15. Install the charge air cooler front manifold.




16. Install the charge air cooler front manifold bolts.

Tighten the charge air cooler front manifold bolt to 10 N.m (89 lb in).

17. Install the remaining portion of the charge air cooler front manifold.
18. Install the front section of the supercharger inlet duct assembly.
19. Fill the charge air cooling system.