Charge Air Cooler

REMOVAL & INSTALLATION

1990–94 Vehicles

1. Disconnect the negative battery cable.
2. Label and disconnect the vacuum hoses at the turbocharger by-pass valve.
3. Remove the air intake hoses and the air cleaner assembly from the engine compartment.
4. Remove the splash shield and extension from the inside of the right front wheel well. Disconnect and remove any remaining air plumbing.
5. Remove the charge air cooler mounting bolts and the charge air cooler from the vehicle.

   Fig. 1: Charge air cooler — 1990–94 2.0L turbocharged engine

   To install:

6. Install the charge air cooler and the charge air cooler mounting bolts Tighten bolts to 11 ft. lbs. (15 Nm).
7. Install the lower air plumbing and the splash shield and extension inside of the right front wheel well.
8. Install the air cleaner assembly and the air intake hoses.
9. Connect the vacuum hoses at the turbocharged by-pass valve and the negative battery cable.
10. Confirm that all air hoses are securely installed and the connections are tight.

1995–98 Vehicles

1. Disconnect the negative battery cable.
2. Remove the front bumper for access to the charge air cooler.
3. Remove the air cleaner assembly.
4. Remove the relay box.

   CAUTION
   Do not allow any foreign matter to get into the hoses while they are disconnected.

5. Disconnect the air bypass and air intake hoses from the air cleaner assembly.
6. Disconnect the air hose and turbocharger bypass valve from the charge air cooler air hose assembly.
7. Detach the air hose from the charge air cooler.
8. Unfasten the duct from the charge air cooler.

   Fig. 2: Charge air cooler removal and installation — 1995–98 2.0L turbocharged engines

9. Remove the charge air cooler from the vehicle, detaching it from the remaining air hose.
10. Inspect the charge air cooler fins for bends, damage or foreign matter and check the hoses for damage. Replace any necessary components.

    To install:

11. Position the charge air cooler in the vehicle.
12. Attach the duct work and hoses disconnected during removal.

    NOTE: When connecting the air hoses and pipes, align the paint marks on the hoses with the projections and indentations on the pipe.

13. Installation of the remaining components is the reverse of the removal procedure.
14. Install the front bumper on the vehicle.
15. The connect the negative battery cable, then start the engine and check for proper operation.