Removal and Replacement

Charge Air Cooler

Charge Air Cooler (CAC)

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Material(s)






Removal

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. Remove the radiator. REFER to Radiator - 2.0L GTDI .

2. Disconnect the CAC (Charge Air Cooler) MAPT (Manifold Absolute Pressure and Temperature) sensor electrical connector.





3. Loosen the clamp and disconnect the CAC (Charge Air Cooler) inlet tube and remove the CAC (Charge Air Cooler).
- To install, tighten clamp to 5 Nm (44 lb-in).





4. If needed, remove the bolt and the MAPT (Manifold Absolute Pressure and Temperature) sensor.
- To install, tighten to 8 Nm (71 lb-in).





Installation

1. NOTE: When installing the CAC (Charge Air Cooler) tubes, thoroughly clean the joint clamp areas as well as the turbocharger connection, engine connection and the CAC (Charge Air Cooler) connections using metal brake parts cleaner.
To install, reverse the removal procedure.