Intercooler Duct: Service and Repair

Charged Air Cooler Hoses/Pipes Replacement

Removal Procedure





1. Remove the left or right wheelhouse inner panel.
2. Remove the air cleaner.
3. Loosen the charged air cooler outlet duct to intake hose clamp (1).

4. Important:
Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

Remove the charged air cooler outlet duct from the intake.





5. Working through the right wheelhouse, loosen the charged air cooler outlet duct clamp at the charged air cooler.
6. Remove the charged air cooler outlet duct.
7. Disassemble the hose and pipe, if required.





8. Loosen the charged air cooler inlet duct to turbocharger clamp (1).

9. Important:
Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.

Remove the charged air cooler inlet duct from the turbocharger.





10. Loosen the charged air cooler inlet duct clamp (3) at the charged air cooler.
11. Remove the charged air cooler inlet duct. The duct can be removed as one piece with the left wheelhouse inner panel removed.
12. Disassemble the hose and pipe, if required.
13. Inspect the hoses for cuts or tears.
14. Inspect the pipes for damage.
15. Replace the hose or pipe if damage is found.

Installation Procedure





1. Install the charged air cooler inlet duct. The duct is marked for correct installation.
2. Install the clamp (3) on the charged air cooler inlet duct but do not tighten.
3. Install the charged air cooler inlet duct to the charged air cooler aligning the marks (2) on the hoses.





4. Remove the tape from the turbocharger openings.
5. Install the charged air cooler inlet duct to the turbocharger.
6. Align the mark on the duct (2) with the mark on the turbocharger.

Notice: Refer to Fastener Notice in Service Precautions.

7. Position the clamp (1) as shown for proper clearance.
^ Tighten the clamp to 6 Nm (53 inch lbs.).





8. Assemble the hose and pipe, if required.
9. Install the charged air cooler outlet duct (2).
10. Working through the right wheelhouse, tighten the charged air cooler outlet duct clamp (1) at the charged air cooler.





11. Install the charged air cooler outlet duct to the intake.
12. Align the mark on the duct (3) with the mark on the intake.
13. Position the clamp (1) as shown for proper clearance.
^ Tighten the clamp to 6 Nm (53 inch lbs.).
14. Install the air cleaner.
15. Install the left or right wheelhouse inner panel.