Intercooler: Service and Repair

CHARGE AIR COOLER

REMOVAL

1. Drain cooling system.
2. Remove air cleaner housing.
3. Disconnect negative battery cable.
4. Disconnect positive battery cable.
5. Remove battery and battery tray.





6. Remove grille.
7. Remove upper radiator closure panel (1) and center brace (2).





8. Remove front bumper fascia.
9. Remove front bumper.
10. Loosen charge air cooler hose clamps. Disconnect charge air cooler hoses
11. Remove radiator fan.
12. Remove charge air cooler fasteners (2).
13. Remove radiator.
14. Remove charge air cooler.

INSTALLATION
1. Position charge air cooler to mounting location.

NOTE: When lowering radiator, make sure lower radiator pins engage properly through charge air cooler tabs.





2. Install radiator.
3. Install fasteners attaching charge air cooler to radiator. Torque fasteners to 8 Nm (70 inch lbs.).
4. Install radiator fan.
5. Connect charge air cooler hoses. Tighten hose clamps to 1.7 Nm (15 inch lbs.).
6. Install front bumper.
7. Install front bumper fascia.
8. Install upper radiator closure panel and center brace.
9. Install grille.
10. Install battery tray and battery.
11. Connect positive battery cable.
12. Connect negative battery cable.
13. Install air cleaner housing.
14. Fill cooling system.