Intercooler: Service and Repair

Intercooler And Components:

For removal of the charge air cooler only, use steps #9, #10, #11, #12.

REMOVAL
1. Disconnect the air bypass hose from the air bypass valve.
2. Disconnect the intake air hose to the air cleaner.
3. Disconnect the vacuum hose to the air cleaner.
4. Disconnect the vacuum hose to the air bypass valve.
5. Disconnect the electrical harness connectors to the air cleaner.
6. Unbolt the air cleaner and secure it out of the way.
7. Remove air hose C.
8. Remove the air pipe with the air bypass valve.
9. Remove air hose B.
10. Remove the splash shield.
11. Remove air hose A.
12. Remove the charge air cooler thru the fenderwell.

INSPECTION
1. Check the charge air cooler fins and tubes for punctures, bends or clogging by foreign matter.
2. Inspect the air hoses and air pipes for cracks, brittleness or punctures.

CAUTION: Be careful not to allow any dirt or other foreign objects to enter the hoses, pipes or charge air cooler.

INSTALLATION
Install in the reverse order of disassembly.

Torque charge air cooler to body: 12 - 15 Nm (9 -11 ft.lbs.)

Torque air pipe mounting bolts: 12 - 15 Nm (9 -11 ft.lbs.)

Torque value, air hose clamps: 4 Nm (3 ft.lbs.)

Intercooler Pipe And Hose Alignment Marks:

NOTE: In the case of disassembly of the entire system, pay special attention to the alignment marks (indicated by the arrows in the image) on the hoses and pipe to obtain a proper fit during assembly.