Charge Air Cooler System

CHARGE AIR COOLER SYSTEM

REMOVAL
1. Remove front bumper.
2. Remove headlamp assemblies.
3. Remove front cross member together with front grille.





4. Remove left and right radiator trim (Fig. 3).
5. Disconnect charge air hoses at charge air cooler (Fig. 3).
6. Disconnect power steering cooler loop from charge air cooler (Fig. 3).
7. Remove charge air cooler from radiator assembly (Fig. 3).

CLEANING

CAUTION: Do not use caustic cleaners to clean the charge air cooler. Damage to the charge air cooler will result.

NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced.

1. If the engine experiences a turbocharger failure or any other situation where oil or debris get into the charge air cooler, the charge air cooler must be cleaned internally.
2. Position the charge air cooler so the inlet and outlet tubes are vertical.
3. Flush the cooler internally with solvent in the direction opposite of normal air flow.
4. Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris.
5. Continue flushing until all debris or oil are removed.
6. Rinse the cooler with hot soapy water to remove any remaining solvent.
7. Rinse thoroughly with clean water and blow dry with compressed air.

INSPECTION
Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. Replace the charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge Air Cooler Tester Kit.

INSTALLATION
1. Install charge air cooler to radiator (Fig. 3).
2. Connect power steering cooler loop to charge air cooler (Fig. 3).
3. Connect charge air hoses (Fig. 3).
4. Install both radiator trim pieces (Fig. 3).
5. Install front grille with front cross member.
6. Install headlamp assemblies.
7. Install front bumper.