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).





3. Disconnect the vacuum hoses (B) and the air bypass outlet connecting tube (C).

4. Remove the charge air cooler assembly.






5. Refer to the Exploded View if needed during this procedure.

Installation

1. Refer to the Exploded View if needed during this procedure.

2. Install the charge air cooler assembly (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.






3. Connect the vacuum hoses (A) and the air bypass outlet connecting tube (B).





4. Connect the turbocharger boost sensor connector (C).

5. Install the charge air cooler cover.