Intercooler: Service and Repair

CHARGE AIR COOLER







Removal
1. Remove the intake manifold.
2. Remove the 4 bolts and the charge air cooler (CAC) coolant tube assembly.
3. Remove the 2 CAC coolant connector tubes and the 4 O-rings.
- Discard the O-rings.

4. Remove the 13 bolts and the lower intake manifold cover and gasket.
5. Remove the 10 bolts and the CAC.

Installation







1. NOTE: Apply threadlock and sealer to the CAC bolts prior to installation.

Position the CAC and install the bolts.
- Tighten the bolts in the sequence shown in 2 stages:
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).







2. NOTE: Inspect the lower intake manifold cover gasket. Install a new gasket if necessary.

Position the gasket and the lower intake manifold cover, and install the bolts.
- Tighten the bolts in the sequence shown:
- Tighten to 10 Nm (89 lb-in).

3. Apply clean engine coolant to the new CAC coolant connector tube O-rings, and install them on the CAC coolant connector tubes.
4. Install the CAC coolant connector tubes.

5. NOTE: Inspect the CAC coolant tube assembly and gasket. Install a new gasket if necessary.

Position the gasket and the CAC coolant tube assembly, and install the bolts.
- Tighten to 10 Nm (89 lb-in).

6. Install the intake manifold.