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 (Charge Air Cooler) 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 (Charge Air Cooler) rail supports and the CAC (Charge Air Cooler).

Installation

1. NOTE: Apply threadlock and sealer to the CAC (Charge Air Cooler) bolts prior to installation.
Position the CAC (Charge Air Cooler) 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 (Charge Air Cooler) coolant connector tube O-ring seals, and install them on the CAC (Charge Air Cooler) coolant connector tubes.

4. Install the CAC (Charge Air Cooler) coolant connector tubes.

5. NOTE: Inspect the CAC (Charge Air Cooler) coolant tube assembly and gasket. Install a new gasket if necessary.
Position the gasket and the CAC (Charge Air Cooler) coolant tube assembly, and install the bolts.

- Tighten to 10 Nm (89 lb-in).


6. Install the intake manifold.