Intercooler: Service and Repair

Charge Air Cooler Replacement

Removal Procedure




1. Remove the charge air cooler inlet and outlet pipes..
2. Remove the radiator.
3. Remove the charge air cooler bolts.

Important: Do not damage the charged air cooler fins while removing.

4. Remove the charge air cooler.

1. Disengage the bottom mounts from the radiator support.
2. Remove the left side from the radiator support.
3. Angle up the right side and rotate in order to remove.

5. Clean the charge air cooler by flushing with mild soap and water. Do not use stream pressure to clean.
6. Inspect the charge air cooler for the following damage:

* Damaged fins
* Cracked or distorted hose connections
* Broken or loose welds
* Leaks in the core or the tank connections

7. Replace the charge air cooler if damage is found.
8. Inspect the charged air cooler mounting insulators and replace if required.

Installation Procedure




1. Install the charge air cooler.

1. Angle in the left side.
2. Slide to the left.
3. Move in the right side.
4. Position bottom insulators in the radiator support.

Notice: Refer to Fastener Notice.

2. Install the charge air cooler bolts.

Tighten the bolts to 21 N.m (15 lb ft).

3. Install the radiator.
4. Install the charge air cooler inlet and outlet pipes.