Charge Air Cooler Bracket Replacement

Removal Procedure

1. Oil Filler Cap » Remove

Charge Air Cooler Bracket Replacement — figure 1

2. Intake Manifold Cover Bolt (1) » Remove
3. Intake Manifold Cover (2) » Remove
4. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.

Charge Air Cooler Bracket Replacement — figure 2

5. Electrical Connector (1) @ Nitrogen Oxides Sensor » Disconnect
6. Wiring Harness Retainer (2) @ Charge Air Cooler » Remove [3x]
7. Electrical Connector (3) @ Charge Air Cooler » Disconnect [2x]
8. Engine Wiring Harness (4) » Reposition

Charge Air Cooler Bracket Replacement — figure 3

9. Wiring Harness Retainer (4) @ Charge Air Cooler » Remove

Charge Air Cooler Bracket Replacement — figure 4

10. Charge Air Cooler Inlet Air Hose Clamp (1) » Loosen until disengaged [2x]
11. Charge Air Cooler Inlet Air Hose (2) » Remove

Charge Air Cooler Bracket Replacement — figure 5

12. Charge Air Cooler Outlet Air Hose Clamp (1) » Loosen until disengaged [2x]
13. Charge Air Cooler Outlet Air Hose (2) » Remove

Charge Air Cooler Bracket Replacement — figure 6

14. Upper Intake Manifold Brace Nut (1) » Remove [3x]
15. Reposition the upper intake manifold bracket (2) with NOx sensor attached.

Charge Air Cooler Bracket Replacement — figure 7

16. Charge Air Cooler Bolt (1) » Remove [4x]

Charge Air Cooler Bracket Replacement — figure 8

17. Reposition the charge air cooler (1) with hoses still attached.

Charge Air Cooler Bracket Replacement — figure 9

18. Turbocharger Heat Shield Bolt (1) » Remove [2x]
19. Turbocharger Heat Shield Nut (2) » Remove

Charge Air Cooler Bracket Replacement — figure 10

20. Turbocharger Heat Shield (1) » Reposition

Charge Air Cooler Bracket Replacement — figure 11

21. Turbocharger Bracket Bolt (1) » Remove
22. Turbocharger Bracket Nut (2) » Remove [2x]
23. Turbocharger Bracket Brace (3) » Remove

Charge Air Cooler Bracket Replacement — figure 12

24. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
25. Engine Wiring Harness Bracket (3) » Reposition

Charge Air Cooler Bracket Replacement — figure 13

26. Oil Filler Tube Support Stud (1) » Remove

Charge Air Cooler Bracket Replacement — figure 14

27. Engine Coolant Air Bleed Hose Clip (1) » Remove

Charge Air Cooler Bracket Replacement — figure 15

28. Charge Air Cooler Bolt (1) » Remove [5x]
29. Charge Air Cooler Bracket (2) » Remove Cleaning and Inspection Procedure - Required

Charge Air Cooler Bracket Replacement — figure 16

1. Inspect the charge air cooler inlet air hose (2): 1.1. Use dish soap and water to clean the inside of the charge air cooler inlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 1.2. Inspect the interior of the charge air cooler inlet air hose (2) for tears or delamination. Replace the hose if damage is found. 1.3. Inspect the charge air cooler inlet air hose clamps (1). Replace the charge air cooler inlet air hose (2) if damage is found or the clamp components are missing.

Charge Air Cooler Bracket Replacement — figure 17

2. Inspect the charge air cooler outlet air hose (2): 2.1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 2.2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found. 2.3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing. Installation Procedure

3. Charge Air Cooler Bracket (2) » Install

Caution

Refer to Fastener Caution.

2. Charge Air Cooler Bolt (1) » Install [5x] — Fastener Specifications

3. Engine Coolant Air Bleed Hose Clip (1) » Install

4. Oil Filler Tube Support Stud (1) » Install — Fastener Specifications

5. Engine Wiring Harness Bracket (3) » Install

6. Engine Wiring Harness Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

7. Turbocharger Bracket Brace (3) » Install

8. Turbocharger Bracket Nut (2) » Install and tighten [2x] — Fastener Specifications

9. Turbocharger Bracket Bolt (1) » Install and tighten — Fastener Specifications

10. Turbocharger Heat Shield (1) » Install

11. Turbocharger Heat Shield Nut (2) » Install and tighten — Fastener Specifications

12. Turbocharger Heat Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

13. Charge Air Cooler (1) » Install

14. Charge Air Cooler Bolt (1) » Install [4x] — Fastener Specifications

15. Install the upper intake manifold bracket (2) with NOx Sensor.

16. Upper Intake Manifold Brace Nut (1) » Install and tighten [3x] — Fastener Specifications

17. Charge Air Cooler Outlet Air Hose (2) » Install

18. Charge Air Cooler Outlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

19. Charge Air Cooler Inlet Air Hose (2) » Install

20. Charge Air Cooler Inlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

21. Wiring Harness Retainer (4) @ Charge Air Cooler » Install

22. Engine Wiring Harness (4) » Reposition

23. Wiring Harness Retainer (2) @ Charge Air Cooler » Install [3x]

24. Electrical Connector (3) @ Charge Air Cooler » Connect [2x]

25. Electrical Connector (1) @ Nitrogen Oxides Sensor » Connect

26. Oil Filler Cap » Remove

27. Intake Manifold Cover (2) » Install

28. Intake Manifold Cover Bolt (1) » Install and tighten — Fastener Specifications

29. Oil Filler Cap » Install