Intercooler: Service and Repair

Charge Air Cooler













Removal

1. Remove the intake manifold.

2. Remove the 4 bolts and the Charge Air Cooler (CAC) coolant tube assembly.

3. Remove the 2 CAC coolant connector tubes and the 4 O-ring seals.
- Discard the O-ring seals.

4. Remove the 13 bolts and the lower intake manifold cover and gasket.

5. Remove the 10 bolts, the 2 CAC rail supports and the CAC.

Installation

1. NOTE: Apply threadlock and sealer to the CAC bolts prior to installation.

Position the CAC and install the support rails and bolts.
- Tighten the bolts in the sequence shown in 2 stages:
- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 10 Nm (89 lb-in).





2. NOTE: Inspect the lower intake manifold cover gasket. Install a new gasket if necessary.

Position the gasket and the lower intake manifold cover, and install the bolts.

- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).





3. Apply clean engine coolant to the new CAC coolant connector tube O-ring seals, and install them on the CAC coolant connector tubes.

4. Install the CAC coolant connector tubes.

5. NOTE: Inspect the CAC coolant tube assembly and gasket. Install a new gasket if necessary.

Position the gasket and the CAC coolant tube assembly, and install the bolts.
- Tighten to 10 Nm (89 lb-in).

6. Install the intake manifold.