Charge Air Cooler Housing Replacement

Charge Air Cooler Housing Replacement

Disassemble Procedure





1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)) .
2. Remove the fuel rail. Refer to Fuel Injector and Fuel Rail Replacement (Service and Repair) .




3. Drain the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling (Static Fill) (Charge Air Cooling System Draining and Filling (Static Fill)) .

Important: Do not allow draining coolant to contact the supercharger drive belt.


4. Place a shop rag under the front portion of the supercharger to catch any remaining coolant.
5. Remove the charge air cooler front manifold. Refer to Charge Air Cooler Front Manifold Replacement (Charge Air Cooler Front Manifold Replacement) .




6. Remove the charge air cooler rear manifold. Refer to Charge Air Cooler Coolant Rear Manifold Replacement (Charge Air Cooler Coolant Rear Manifold Replacement) .
7. Remove the charge air cooler cooling tubes, if necessary. Refer to Charge Air Cooler Cooling Tube Replacement (Charge Air Cooler Cooling Tube Replacement) .




8. Remove the long charge air cooler bolts.




9. Remove the short charge air cooler perimeter bolts.




10. Remove the charge air cooler housing.




11. Remove and discard the charge air cooler housing perimeter gasket.
12. Remove and discard the charge air cooler housing interior O-ring gaskets.



Installation Procedure





1. Install the NEW charge air cooler housing interior O-ring gaskets.
2. Install the NEW charge air cooler housing perimeter gasket.




3. Install the charge air cooler housing.





Notice: Refer to Fastener Notice (Fastener Notice) .

4. Install the long charge air cooler bolts.

Tighten the long charge air cooler bolt to 10 N.m (89 lb in).





5. Install the short charge air cooler perimeter bolts.

Tighten the short charge air cooler bolt to 10 N.m (89 lb in).





6. Install the charge air cooler cooling tubes, if necessary. Refer to Charge Air Cooler Cooling Tube Replacement (Charge Air Cooler Cooling Tube Replacement) .
7. Install the charge air cooler rear manifold. Refer to Charge Air Cooler Coolant Rear Manifold Replacement (Charge Air Cooler Coolant Rear Manifold Replacement) .




8. Install the charge air cooler front manifold. Refer to Charge Air Cooler Front Manifold Replacement (Charge Air Cooler Front Manifold Replacement) .
9. Fill the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling (Static Fill) (Charge Air Cooling System Draining and Filling (Static Fill)) .




10. Install the fuel rail. Refer to Fuel Injector and Fuel Rail Replacement (Service and Repair) .
11. Install the fuel fill cap.
12. Check the charge air cooling system for leaks.
13. Check the fuel system for leaks.