CHARGE AIR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement Part

O-ring
 
Quantity: 1
 
Location of use: Charge air cooler air outlet pipe
O-ring
 
Quantity: 1
 
Location of use: Charge air cooler air inlet pipe

Oil and Chemical Type

Engine oil
 
Type: Recommended oil

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION.)

3.  Remove the front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

4.  Remove the boost air temperature sensor. (See BOOST AIR TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove in the order shown in the figure.

6.  Install in the reverse order of removal.

Fuel injector (2pin type)

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1
Charge air cooler outlet pipe
2
Charge air cooler inlet pipe
(See Charge Air Cooler Inlet Pipe Installation Note.)
3
Charge air cooler
(See Charge Air Cooler Installation Note.)
4
Protector

Fuel injector (6pin type)

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1
Charge air cooler outlet pipe
2
Charge air cooler inlet pipe
(See Charge Air Cooler Inlet Pipe Installation Note.)
3
Charge air cooler
(See Charge Air Cooler Installation Note.)
4
Protector


Charge Air Cooler Installation Note

1.  Remove foreign matter on the O-ring seal surface of charge air cooler and in the pipe furrow O-ring (sand or dust).

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Note
•  The color is different between the O-ring on the charge air cooler outlet pipe side and the O-ring on the charge air cooler inlet pipe side. Verify the color before installing the O-ring.

2.  Align the O-ring projection with the pipe furrow and install the O-ring.

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Color of O-ring
Charge air cooler outlet pipe side: Blue color
Charge air cooler inlet pipe side: Black color

3.  Temporarily install the bolts and nuts shown in the diagram.

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4.  Tighten the charge air cooler in the order shown in the figure.

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Charge Air Cooler Inlet Pipe Installation Note

1.  Clean the seal surface and furrow area of the charge air cooler air inlet pipe.

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2.  Degrease the seal surface of the pipe, and verify if there is foreign matter penetration or scratches.

•  If there is foreign matter penetration or scratches, replace the pipe.

3.  Apply engine oil to the seal surface of the pipe.

Note
•  Make sure that the installation direction of the charge air cooler hose is correct and verify the marking shown in the figures.
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4.  Align the pipe rib and connector groove positions, and install.

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5.  Insert the pipe connector completely into the connector.

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6.  Pull the pipe outward and verify that a click sound is heard.

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