Charge Air Cooler Replacement
Removal Procedure
  1. Drain the charge air cooling system.Charge Air Cooling System Draining and Filling
  2. Oil Filler Cap»Remove

    3. Object ID: 5171779
  3. Intake Manifold Cover Bolt(1)»Remove
  4. Intake Manifold Cover(2)»Remove
  5. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.

    6. Object ID: 5624867
  6. Electrical Connector(1)@Nitrogen Oxides Sensor»Disconnect
  7. Wiring Harness Retainer(2)@Charge Air Cooler»Remove[3x]
  8. Electrical Connector(3)@Charge Air Cooler»Disconnect[2x]
  9. Engine Wiring Harness(4)»Position aside

    10. Object ID: 5624929
  10. Hose Clamp(1)»Disengage[2x]—Hose Clamp Replacement Guidelines - Spring Type
  11. Charge Air Cooler Coolant Pump Hose(2)@Charge Air Cooler»Remove
  12. Charge Air Cooler Coolant Hose(3)@Charge Air Cooler»Remove
  13. Wiring Harness Retainer(4)@Charge Air Cooler»Remove

    14. Object ID: 5211389
  14. Charge Air Cooler Inlet Air Hose Clamp(1)»Loosen until disengaged[2x]
  15. Charge Air Cooler Inlet Air Hose(2)»Remove

    16. Object ID: 5211335
  16. Charge Air Cooler Outlet Air Hose Clamp(1)»Loosen until disengaged[2x]
  17. Charge Air Cooler Outlet Air Hose(2)»Remove

    18. Object ID: 5217133
  18. Charge Air Cooler Bolt(1)»Remove[4x]

    19. Object ID: 5217156
  19. Charge Air Cooler(1)»Remove
  20. Remove the injector flow identifier information label, using a heat gun.

    21. Object ID: 5840604
  21. Charge Air Cooler Air Temperature Sensor(1)»Remove
  22. Charge Air Temperature Secondary Sensor (2)»Remove
Cleaning and Inspection Procedure - Required

    Object ID: 5854827
  1. Inspect the charge air cooler inlet air hose (2):
    1. Use dish soap and water to clean the inside of the charge air cooler inlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces.
    2. Inspect the interior of the charge air cooler inlet air hose (2) for tears or delamination. Replace the hose if damage is found.
    3. Inspect the charge air cooler inlet air hose clamps (1). Replace the charge air cooler inlet air hose (2) if damage is found or the clamp components are missing.

    Object ID: 5854825
  2. Inspect the charge air cooler outlet air hose (2):
    1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces.
    2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found.
    3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing.
Installation Procedure

    Object ID: 5840604

    Caution: Refer to Component Fastener Tightening Caution.

  1. Charge Air Temperature Secondary Sensor (2)»Install and tighten—Fastener Specifications
  2. Charge Air Cooler Air Temperature Sensor(1)»Install and tighten—Fastener Specifications
  3. Install the injector flow identifier information label.

    4. Object ID: 5217156
  4. Charge Air Cooler(1)»Install

    5. Object ID: 5217133

    Caution: Refer to Fastener Caution.

  5. Charge Air Cooler Bolt(1)»Install and tighten[4x]—Fastener Specifications

    6. Object ID: 5211335
  6. Charge Air Cooler Outlet Air Hose(2)»Install
  7. Charge Air Cooler Outlet Air Hose Clamp(1)»Tighten[2x]—Fastener Specifications

    8. Object ID: 5211389
  8. Charge Air Cooler Inlet Air Hose(2)»Install
  9. Charge Air Cooler Inlet Air Hose Clamp(1)»Tighten[2x]—Fastener Specifications

    10. Object ID: 5624929
  10. Wiring Harness Retainer(4)@Charge Air Cooler»Install
  11. Charge Air Cooler Coolant Hose(3)@Charge Air Cooler»Install
  12. Charge Air Cooler Coolant Pump Hose(2)@Charge Air Cooler»Install
  13. Hose Clamp(1)»Engage[2x]—Hose Clamp Replacement Guidelines - Spring Type

    14. Object ID: 5624867
  14. Engine Wiring Harness(4)»Reposition
  15. Wiring Harness Retainer(2)@Charge Air Cooler»Install[3x]
  16. Electrical Connector(3)@Charge Air Cooler»Connect[2x]
  17. Electrical Connector(1)@Nitrogen Oxides Sensor»Connect

    18. Object ID: 5171779
  18. Oil Filler Cap»Remove
  19. Intake Manifold Cover(2)»Install
  20. Intake Manifold Cover Bolt(1)»Install and tighten—Fastener Specifications
  21. Oil Filler Cap»Install
  22. Fill the charge air cooling system and inspect for leaks. Charge Air Cooling System Draining and Filling