Charge Air Cooler Housing Replacement

Charge Air Cooler Housing Replacement

Disassemble Procedure




1. Relieve the fuel system pressure.
2. Remove the fuel rail.




3. Drain the charge air cooling system.

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

4. Place a shop rag under the front portion of the supercharger to catch any remaining coolant.
5. Remove the charge air cooler front manifold.




6. Remove the charge air cooler rear manifold.
7. Remove the charge air cooler cooling tubes, if necessary.




8. Remove the long charge air cooler bolts.




9. Remove the short charge air cooler perimeter bolts.




10. Remove the charge air cooler housing.




11. Remove and discard the charge air cooler housing perimeter gasket.
12. Remove and discard the charge air cooler housing interior O-ring gaskets.

Installation Procedure




1. Install the NEW charge air cooler housing interior O-ring gaskets.
2. Install the NEW charge air cooler housing perimeter gasket.




3. Install the charge air cooler housing.





Notice: Refer to Fastener Notice.

4. Install the long charge air cooler bolts.

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




5. Install the short charge air cooler perimeter bolts.

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




6. Install the charge air cooler cooling tubes, if necessary.
7. Install the charge air cooler rear manifold.




8. Install the charge air cooler front manifold.
9. Fill the charge air cooling system.




10. Install the fuel rail.
11. Install the fuel fill cap.
12. Check the charge air cooling system for leaks.
13. Check the fuel system for leaks.