Intercooler: Service and Repair

Charge Air Cooler Removal and Installation

Charge Air Cooler:

Removal
1. Remove the charge air cooler cover.





2. Disconnect the turbocharger boost sensor connector (A), then remove the vacuum hoses (B) and air bypass outlet connecting tube (C).





3. Remove the charge air cooler.





Installation
1. Install the charge air cooler (A), and set the intake air ducts (charge air cooler inlet hose and charge air cooler outlet tube), then tighten the hose bands until the edge (B) of the hose band align with the mark (C) on the hose band.

NOTE: If the hose band edge exceeds the mark, replace the hose band.





2. Install the vacuum hoses (A) and air bypass outlet connecting tube (B), then connect the turbocharger boost sensor connector (C).





3. Install the charge air cooler cover.