Intercooler: Service and Repair

Charge Air Cooler

Charge Air Cooler (CAC) Pipes and Tubes





Item Part Number Description

1 - Charge Air Cooler (CAC)-to-throttle body tube spring clip (part of 6F073)

2 6F073 CAC-to-throttle body pipe

3 - RH turbocharger-to-CAC tube clamp - 5 Nm (44 lb-in) (part of 6C646)

4 - RH turbocharger-to-CAC tube (part of 6C646)

5 - LH turbocharger-to-CAC tube clamp - 5 Nm (44 lb-in) (part of 6C646)

6 - LH turbocharger-to-CAC tube (part of 6C646)





Item Part Number Description

1 W503943 Charge Air Cooler (CAC) bracket bolt - 40 Nm (30 lb-ft) (2 required)

2 6K864 CAC bracket

3 6K775 CAC

4 19E672 CAC shield

5 - CAC shield pushpins (4 required) (part of 19E672)

Removal and Installation

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle jacking and lifting.

2. Turn the 4 quarter-turn retainers, detach the 8 pushpins and remove the lower air deflector.





3. Remove the 2 nuts and the air dam.

- To install, tighten to 20 Nm (177 lb-in).





4. Loosen the clamps and disconnect the turbocharger-to-Charge Air Cooler (CAC) tubes from the CAC.

- To install, tighten to 5 Nm (44 lb-in).

5. Remove the spring clip and disconnect the CAC-to-throttle body tube from the CAC.

6. Remove the 2 bolts, the Charge Air Cooler (CAC) bracket and the CAC.

- To install, tighten to 40 Nm (30 lb-ft).

7. If a new CAC is being installed, remove the 4 pushpins and the shield.

8. To install, reverse the removal procedure