Intercooler: Service and Repair

CHARGE AIR COOLER

REMOVAL
1. Drain the supercharger coolant.
2. Release the fuel pressure.






3. Disconnect the supercharger degas hose.







4. Disconnect the coolant hose.
5. Remove the supercharger belt.
6. Remove the air cleaner outlet tube.







7. Disconnect the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve electrical connectors.







8. Disconnect the vacuum hose.
9. Disconnect the fuel supply spring lock coupler.







10. Disconnect the accelerator controls.
- Disconnect the accelerator cable.
- If equipped, disconnect the speed control cable.







11. Remove the accelerator cable bracket bolts.







12. Remove the throttle body and spacer assembly.







13. Release the clip and position the accelerator cable bracket and the cables aside.







14. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.







15. Disconnect the vacuum hoses from the differential pressure feedback EGR system.







16. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the actuator.







17. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.







18. Disconnect the vacuum hose from the EGR valve.







19. Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside.







20. Remove the vacuum accessory bracket mounting nut.







21. Remove the mounting bolts, and the vacuum accessory bracket.







22. Disconnect the exhaust manifold to EGR valve tube.







23. Disconnect the Barometric Pressure (BARO) sensor electrical connector.







24. Disconnect the Positive Crankcase Ventilation (PCV) hose.







25. Separate the fuel charging wiring harness from the fuel injection supply manifold in four places and position the harness aside.







26. Remove the ten bolts, the intake manifold, supercharger and fuel supply manifold as an assembly.







27. Disconnect and remove the PCV hoses.







28. Remove the coolant supply and return manifold.







29. Remove the coolant supply and return tubes and seals.







30. Remove the fuel supply manifold mounting studs.







31. Remove the fuel supply manifold and fuel injectors as an assembly.







32. Remove the bolts, the supercharger and Charge Air Cooler (CAC) assembly.







33. Remove the bolts and the CAC in the sequence shown.







34. Inspect the CAC plenum gasket and install a new gasket if necessary.

INSTALLATION
1. To install, reverse the removal procedure.







2. Apply a bead of sealant in the areas shown on the supercharger flange between the CAC and the supercharger.







3. Tighten the CAC bolts in the sequence shown in two stages.
1 Tighten to 2 Nm (18 lb-in).
2 Tighten to 6 Nm (53 lb-in).

NOTE: Once the torque procedure has been started, final tightening must be finished within five minutes maximum.







4. Tighten the supercharger and CAC cooler assembly-to-lower intake manifold bolts in the sequence shown in three stages.
1 Tighten to 2 Nm (18 lb-in).
2 Tighten to 25 Nm (18 lb-ft).
3 Tighten an additional 90 degrees.







5. Tighten the coolant supply and return manifold in two stages.
1 Tighten to 10 Nm (89 lb-ft).
2 Tighten an additional 90 degrees.







6. Tighten the lower intake manifold bolts in the sequence shown.

NOTE: Inspect the intake manifold gaskets and install new gaskets, if necessary.

7. Fill and bleed the supercharger cooling system.