Charge Air Cooler Bracket Replacement
Removal Procedure
  1. Oil Filler Cap»Remove

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

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

    9. Object ID: 5624929
  9. Wiring Harness Retainer(4)@Charge Air Cooler»Remove

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

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

    14. Object ID: 5187895
  14. Upper Intake Manifold Brace Nut(1)»Remove[3x]
  15. Reposition the upper intake manifold bracket (2) with NOx sensor attached.

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

    17. Object ID: 5217156
  17. Reposition the charge air cooler (1) with hoses still attached.

    18. Object ID: 5624990
  18. Turbocharger Heat Shield Bolt(1)»Remove[2x]
  19. Turbocharger Heat Shield Nut(2)»Remove

    20. Object ID: 5625005
  20. Turbocharger Heat Shield(1)»Reposition

    21. Object ID: 5138644
  21. Turbocharger Bracket Bolt(1)»Remove
  22. Turbocharger Bracket Nut(2)»Remove[2x]
  23. Turbocharger Bracket Brace(3)»Remove

    24. Object ID: 5499646
  24. Engine Wiring Harness Bracket Nut(1)»Remove[2x]
  25. Engine Wiring Harness Bracket(3)»Reposition

    26. Object ID: 5217555
  26. Oil Filler Tube Support Stud(1)»Remove

    27. Object ID: 5499644
  27. Engine Coolant Air Bleed Hose Clip(1)»Remove

    28. Object ID: 5217574
  28. Charge Air Cooler Bolt(1)»Remove[5x]
  29. Charge Air Cooler Bracket(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: 5217574
  1. Charge Air Cooler Bracket(2)»Install

    2. Caution: Refer to Fastener Caution.

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

    3. Object ID: 5499644
  3. Engine Coolant Air Bleed Hose Clip(1)»Install

    4. Object ID: 5217555
  4. Oil Filler Tube Support Stud(1)»Install—Fastener Specifications

    5. Object ID: 5499646
  5. Engine Wiring Harness Bracket(3)»Install
  6. Engine Wiring Harness Bracket Nut(1)»Install and tighten[2x]—Fastener Specifications

    7. Object ID: 5138644
  7. Turbocharger Bracket Brace(3)»Install
  8. Turbocharger Bracket Nut(2)»Install and tighten[2x]—Fastener Specifications
  9. Turbocharger Bracket Bolt(1)»Install and tighten—Fastener Specifications

    10. Object ID: 5625005
  10. Turbocharger Heat Shield(1)»Install

    11. Object ID: 5624990
  11. Turbocharger Heat Shield Nut(2)»Install and tighten—Fastener Specifications
  12. Turbocharger Heat Shield Bolt(1)»Install and tighten[2x]—Fastener Specifications

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

    14. Object ID: 5217133
  14. Charge Air Cooler Bolt(1)»Install[4x]—Fastener Specifications

    15. Object ID: 5187895
  15. Install the upper intake manifold bracket (2) with NOx Sensor.
  16. Upper Intake Manifold Brace Nut(1)»Install and tighten[3x]—Fastener Specifications

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

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

    21. Object ID: 5624929
  21. Wiring Harness Retainer(4)@Charge Air Cooler»Install

    22. Object ID: 5624867
  22. Engine Wiring Harness(4)»Reposition
  23. Wiring Harness Retainer(2)@Charge Air Cooler»Install[3x]
  24. Electrical Connector(3)@Charge Air Cooler»Connect[2x]
  25. Electrical Connector(1)@Nitrogen Oxides Sensor»Connect

    26. Object ID: 5171779
  26. Oil Filler Cap»Remove
  27. Intake Manifold Cover(2)»Install
  28. Intake Manifold Cover Bolt(1)»Install and tighten—Fastener Specifications
  29. Oil Filler Cap»Install