Charge Air Cooler Replacement

Charge Air Cooler Replacement

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement Service and Repair.

3. Remove the front intake air duct deflector.




4. Remove the front intake air duct bolt (2).

5. Remove the front intake air duct (1).

6. Remove the radiator air seal.

7. Disconnect the air conditioning refrigerant pressure sensor wiring harness plug from the air conditioning condenser.




8. Unclip the 2 radiator protector fenders (2) from the radiator (1).




9. Remove the 3 power steering fluid cooling loop pipe bracket hose clamp nuts (2, 4).

10. Remove the 3 hose clamps (5).

11. Remove the 2 power steering fluid cooling loop pipe bracket bolts (3, 6).

12. Remove the 2 power steering fluid cooling loop pipe brackets (1).




13. Remove the charge air cooler inlet hose (1) from the charge air cooler (2).




14. Remove the charge air cooler outlet hose (2) from the charge air cooler (1).




15. Remove the transmission fluid auxiliary cooler bolt (3).

16. Unclip the transmission fluid cooler pipes (2) from the charge air cooler.

17. Unclip the transmission fluid cooler (1) from the charge air cooler and lay aside.





Note: Handle the cooling module with care.

18. Remove the condenser (3) from the charge air cooler (2) and secure with safety belts.

19. Remove the charge air cooler (2) in top direction from the radiator (1).

Installation Procedure





Note: Handle the cooling module with care.

1. Install the charge air cooler (2) to the radiator (1).

2. Remove the safety belts and install the condenser (3) to the charge air cooler (2).




3. Clip the transmission fluid cooler (1) to the charge air cooler.

4. Clip the transmission fluid cooler pipes (2) to the charge air cooler.

Caution: Refer to Fastener Caution Fastener Caution.

5. Install the transmission fluid auxiliary cooler bolt (3) and tighten.




6. Install the charge air cooler outlet hose (2) to the charge air cooler (1).




7. Install the charge air cooler inlet hose (1) to the charge air cooler (2).




8. Install the 2 power steering fluid cooling loop pipe brackets (1).

9. Install the 2 power steering fluid cooling loop pipe bracket bolts (3, 6) and tighten to 9 Nm (80 lb in).

10. Install the 3 hose clamps (5).

11. Install the 3 power steering fluid cooling loop pipe bracket hose clamp nuts (2, 4) and tighten to 9 Nm (80 lb in).




12. Clip in the 2 radiator protector fenders (2) to the radiator (1).

13. Connect the air conditioning refrigerant pressure sensor wiring harness plug to the air conditioning condenser.

14. Install the radiator air seal.




15. Install the front intake air duct (1).

16. Install the front intake air duct bolt (2) and tighten.

17. Install the front intake air duct deflector.

18. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement Service and Repair.

19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.