Intercooler: Service and Repair

Charge Air Cooler Removal and Installation

Exploded View





Removal

1. Remove the charge air cooler cover.






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






3. Remove the charge air cooler.






Installation

1. Install the charge air cooler (A), and connect the intake air ducts (charge air cooler inlet hose and charge air cooler outlet tube). Tighten the hose bands until the edge (B) of the band align with the mark (C) on the band.
NOTE: If the hose band edge exceeds the mark, replace the hose band.






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






3. Install the charge air cooler cover.