Charge Air Cooler Front Manifold Replacement

Charge Air Cooler Front Manifold Replacement

Removal Procedure

1. Remove the hood. Refer to Hood Replacement (Service and Repair) .
2. Remove the engine sight shield. Refer to Intake Manifold Sight Shield Replacement (Service and Repair) .
3. Remove the front supercharger inlet duct assembly. Refer to Supercharger Inlet Duct Assembly Replacement (Supercharger Inlet Duct Assembly Replacement) .
4. 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 coolant to contact the supercharger drive belt.


Place a shop rag under the front portion of the supercharger to catch any remaining coolant.






5. Remove the charge air cooler hoses from the front section of the charge air cooler front manifold.
6. Remove the bolts (1) and remove the front portion of the supercharger front manifold (2). Discard the manifold O-ring seals.




7. Remove the supercharger bypass regulator solenoid valve and bracket. Refer to Charge Air Bypass Regulator Solenoid Valve Replacement (Charge Air Bypass Regulator Solenoid Valve Replacement) .

Important: The remaining section of the front manifold and the rear manifold must be serviced together. If only one manifold is serviced, there is a possibility of unseating the O-ring seals on the opposite manifold.






8. Remove the charge air cooler front manifold bolts.




9. Remove the charge air cooler front manifold.




10. Remove and discard the charge air cooler front manifold gasket.




11. Remove and discard the charge air cooler cooling tube front O-rings.




12. Remove the charge air cooler cooling tube front spacers if required.




13. Remove the charge air cooler rear manifold bolts.




14. Remove the charge air cooler rear manifold.




15. Remove and discard the charge air cooler rear manifold gaskets.




16. Remove and discard the charge air cooler cooling tube rear O-rings.




17. Remove the charge air cooler cooling tube rear spacers, if required.
18. Remove the inboard and outboard charge air cooling tubes, if required. Refer to Charge Air Cooler Cooling Tube Replacement (Charge Air Cooler Cooling Tube Replacement) .
19. Clean and inspect the charge air cooler manifolds and cooling tubes. Refer to Supercharger Cleaning and Inspection (Overhaul) .



Installation Procedure


Important: The charge air cooler cooling tubes must be installed with the restrictor plates and notch facing the proper directions.


1. Install the charge air cooling tubes, if previously removed. Refer to Charge Air Cooler Cooling Tube Replacement (Charge Air Cooler Cooling Tube Replacement) .




2. Install the charge air cooler cooling tube rear spacers, if previously removed.




3. Install the NEW charge air cooler cooling tube rear O-rings.




4. Install the NEW charge air cooler rear manifold gaskets.




5. Install the charge air cooler rear manifold.




6. Install the charge air cooler rear manifold bolts.

Tighten the charge air cooler rear manifold bolts to 10 N.m (89 lb in).





7. Install the charge air cooler cooling tube front spacers, if previously removed.




8. Install the NEW charge air cooler cooling tube front O-rings.




9. Install the NEW charge air cooler front manifold gasket.




10. Install the charge air cooler front manifold.




11. Install the charge air cooler front manifold bolts.

Tighten the charge air cooler front manifold bolts to 10 N.m (89 lb in).





12. Install the supercharger bypass regulator solenoid valve and bracket. Refer to Charge Air Bypass Regulator Solenoid Valve Replacement (Charge Air Bypass Regulator Solenoid Valve Replacement) .




13. Using NEW O-ring seals, install the front portion of the charge air cooler front manifold (2).
14. Install the manifold bolts (1).

Tighten the charge air cooler front manifold bolts to 10 N.m (89 lb in).

15. Install the charge air cooler hoses to the front section of the charge air cooler front manifold.
16. 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)) .
17. Install the front supercharger inlet duct assembly. Refer to Supercharger Inlet Duct Assembly Replacement (Supercharger Inlet Duct Assembly Replacement) .
18. Install the engine sight shield. Refer to Intake Manifold Sight Shield Replacement (Service and Repair) .
19. Install the hood. Refer to Hood Replacement (Service and Repair) .