Nissan GT-R (R35) · Service Manual ENGINE

CHARGE AIR COOLER

Exploded View



NNBIA0196GB.JPG

1.
 		Air inlet hose (bank 1)
 		2.
 		Clamp
 		3.
 		Turbocharger boost sensor
4.
 		Recirculation pipe (bank 1)
 		5.
 		Gasket
 		6.
 		Clamp
7.
 		Recirculation hose (bank 1)
 		8.
 		Recirculation valve
 		9.
 		Clamp
10.
 		Air inlet hose
 		11.
 		Air inlet pipe assembly (bank 1)
 		12.
 		Air inlet hose (bank 1)
13.
 		Charge air cooler assembly (bank 1)
 		14.
 		Grommet
 		15.
 		Charge air cooler assembly (bank 2)
16.
 		Air inlet hose (bank 2)
 		17.
 		Air inlet pipe assembly (bank 2)
 		18.
 		Recirculation pipe (bank 2)
19.
 		Air inlet hose (bank 2)
 		20.
 		Recirculation hose (bank 2)
 		21.
 		Air inlet hose (bank 2)
22.
 		Clamp
 		23.
 		Air inlet hose
24.
 		Air inlet pipe (bank 2)
25.
 		Bracket
 		26.
 		Air inlet pipe (bank 1)
 		27.
 		Air inlet hose (bank 1)
A.
 		To electric throttle control actuator (bank 1)
 		B.
 		To intake manifold collector
 		C.
 		To exhaust manifold and turbocharger assembly (bank 1) (upper)
D.
 		To exhaust manifold and turbocharger assembly (bank 2) (upper)
 		E.
 		To electric throttle control actuator (bank 2)
 		F.
 		To exhaust manifold and turbocharger assembly (bank 2)
G.
 		To exhaust manifold and turbocharger assembly (bank 1)



Refer to Components for symbols in the figure.

Removal and Installation

 
 REMOVAL

    1.Remove air cleaner case and air duct assembly. Refer to Exploded View.
    2.Disconnect turbocharger boost sensor harness connector.
    3.Disconnect air inlet hose to remove the turbocharger boost sensor and the integrated recirculation valve and pipe.
    NOTE：
    Mark with paint for a reference purpose before removal.
    4.Remove front bumper. Refer to Exploded View.
    5.Remove air intake duct assembly. Refer to Exploded View (GT-R certified NISSAN dealer).
    6.Disconnect air inlet hose and pipe to remove the charge air cooler assembly.
    ■ CAUTION ■
    Never damage or scratch charge air cooler core when removing.
 
 INSTALLATION

Note the following, and install in the reverse order of removal.
 
 AIR INLET HOSE ASSEMBLY


NNBIA0202ZZ.JPG

A.
Matching mark (blue)
B.
Matching mark (yellow)
C.
Matching mark (pink)

: Vehicle front





  • To install each part, refer to the above figure to align the matching marks.
  • Temporarily assemble all the removed parts before tightening the clamp.
  • Tighten the clamp to the specified torque as shown below:
    Clamp tightening torque
    		: 4.6 N·m (0.47 kg-m, 41 in-lb)

■ CAUTION ■
Never use air tool or power tools for tightening.
 
 AIR INLET PIPE ASSEMBLY

  • Install air inlet pipe assembly as follows:
    NNBIA0195ZZ.JPG

1
: Air inlet pipe assembly (bank 1)
2
: Air inlet pipe assembly (bank 2)

    1.Tighten bolt (A) (temporarily).
    2.Tighten bolt (B) (temporarily).
    3.Tighten bolt (C) (specified torque).
    4.Tighten bolt (A) (specified torque).
    5.Tighten bolt (B) (specified torque).

Inspection

 
 INSPECTION AFTER REMOVAL
 
 Recirculation Valve

  • Check that diaphragm lifts and the valve (B) opens when applying negative pressure with a handy vacuum pump (commercial service tool) (A).
    NNBIA0201ZZ.JPG

    Standard
    		: Refer to Recirculation Valve (GT-R certified NISSAN dealer).

  • If it exceeds the standard, replace recirculation valve.
 
 Checking Charge Air Cooler

  • Visually check that there is no incident and damage on the charge air cooler core and air tank (upper side and lower side).
  • If there is an unusual condition, replace the charge air cooler.
 
 Cleaning Charge Air Cooler

Check charge air cooler for mud or clogging. If necessary, clean charge air cooler as follows:
■ CAUTION ■
  • Be careful not to bend or damage the charge air cooler fins.
  • When charge air cooler is cleaned without removal, remove all surrounding parts such as cooling fan shroud and horns. Then tape the harness and connectors to prevent water from entering.

    1.Apply water by hose to the back side of the charge air cooler core vertically download.
    • Apply water again to all charge air cooler core surfaces once per minute.
    • Stop washing if any stains no longer flow out from the charge air cooler.
    2.Blow air into the back side of charge air cooler core vertically download.
    • Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm (11.81 in).
    • Blow air again into all the charge air cooler core surfaces once per minute until no water sprays out.