Charge Air Cooler Replacement

Removal Procedure

1. Drain the charge air cooling system. Charge Air Cooling System Draining and Filling
2. Oil Filler Cap » Remove

Charge Air Cooler Replacement — figure 1

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

Charge Air Cooler Replacement — figure 2

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

Charge Air Cooler Replacement — figure 3

10. Hose Clamp (1) » Disengage [2x] — Hose Clamp Replacement Guidelines - Spring Type
11. Charge Air Cooler Coolant Pump Hose (2) @ Charge Air Cooler » Remove
12. Charge Air Cooler Coolant Hose (3) @ Charge Air Cooler » Remove
13. Wiring Harness Retainer (4) @ Charge Air Cooler » Remove

Charge Air Cooler Replacement — figure 4

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

Charge Air Cooler Replacement — figure 5

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

Charge Air Cooler Replacement — figure 6

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

Charge Air Cooler Replacement — figure 7

19. Charge Air Cooler (1) » Remove
20. Remove the injector flow identifier information label, using a heat gun.

Charge Air Cooler Replacement — figure 8

21. Charge Air Cooler Air Temperature Sensor (1) » Remove
22. Charge Air Temperature Secondary Sensor (2) » Remove Cleaning and Inspection Procedure - Required

Charge Air Cooler Replacement — figure 9

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 Replacement — figure 10

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

Caution

Refer to Component Fastener Tightening Caution.

1. Charge Air Temperature Secondary Sensor (2) » Install and tighten — Fastener Specifications

2. Charge Air Cooler Air Temperature Sensor (1) » Install and tighten — Fastener Specifications

3. Install the injector flow identifier information label.

4. Charge Air Cooler (1) » Install

Caution

Refer to Fastener Caution.

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

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

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

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

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

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

11. Charge Air Cooler Coolant Hose (3) @ Charge Air Cooler » Install

12. Charge Air Cooler Coolant Pump Hose (2) @ Charge Air Cooler » Install

13. Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

14. Engine Wiring Harness (4) » Reposition

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

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

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

18. Oil Filler Cap » Remove

19. Intake Manifold Cover (2) » Install

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

21. Oil Filler Cap » Install

22. Fill the charge air cooling system and inspect for leaks. Charge Air Cooling System Draining and Filling