Charge Air Cooler

Charge Air Cooler
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures How to Use TAS Procedures

Removal

NOTE:
Removal steps in this procedure may contain installation details.
1 Disconnect the battery ground cable.
For additional information, refer to Specifications Battery and Charging System

WARNING: Make sure to support the vehicle with axle stands.
2 Raise and support the vehicle.
For additional information, refer to Cooling System Draining, Filling and Bleeding - Vehicles With: Supercharger
For additional information, refer to Engine Cover - 5.0L Service and Repair
For additional information, refer to Plenum Chamber Service and Repair
For additional information, refer to Fuel Injection Component Cleaning Fuel Injection Component Cleaning
For additional information, refer to Fuel System Pressure Release - 5.0L Service and Repair

CAUTION: Be prepared to collect escaping fluids.

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

CAUTION: Make sure that the fuel line union does not rotate.

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.

Torque to: 10 Nm

NOTE:
Remove and discard the gasket.

Installation
1 To install, reverse the removal procedure.

NOTE:
Install and finger tighten bolts in sequence illustrated.

NOTE:
Tighten the bolts in the indicated sequence.

NOTE:
Install a new gasket.

Torque to: 25 Nm

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

CAUTION: Lubricate only the union threads with clean engine oil.

NOTE:
Do not tighten at this stage.

NOTE:
Remove and discard the blanking caps.

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.
Union: 21 Nm
M6: 12 Nm

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

WARNING: After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury.

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.

Torque to: 21 Nm