CHARGE AIR COOLER AND PLUMBING
DESCRIPTION
The charge air system consists of a inlet air compressor which is part of the turbocharger housing, charge air cooler locate in front of the radiator, and charge air cooler plumbing. The is also a electronic control valve placed after the charge air cooler, inline, that assists with air flow during the EGR operating mode.
The charge air cooler is a heat exchanger that uses air flow from vehicle motion to dissipate heat from the intake air. As the turbocharger increases air pressure, the air temperature increases. Lowering the intake air temperature increases engine efficiency and power. Refer to (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM - OPERATION).
OPERATION
Intake air is drawn through the air cleaner and into the turbocharger compressor housing. Once inside the housing the air is compressed by the rotation of the turbine wheel. The turbine wheel is driven by exhaust gasses, Refer to (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM - OPERATION) to understand the turbine speed operation.
This air compression process causes heat. Pressurized air (charge air) from the turbocharger then flows forward through the charge air cooler, located in front of the radiator, to be cooled by the air flow from vehicle motion rushing past the cooler fins. From the charge air cooler the air flows back into the intake manifold, past an air control valve that assists in EGR mode. There are also resonators located in the charge air stream that assist with air flow and noise suppression.
REMOVAL - CHARGE AIR COOLER
WARNING: IF THE ENGINE WAS JUST TURNED OFF, THE AIR INTAKE SYSTEM TUBES MAY BE HOT.
NOTE: Note the location of the rubber air charge cooler to A/C condenser and air charger cooler to radiator air seals. The seals are use to prevent overheating and improve charge air and A/C efficiency.
1. Disconnect the battery negative cables.
2. Remove cooling module (Refer to 7 - COOLING/ENGINE/RADIATOR - REMOVAL).
3. Remove the front grill.
4. Mark the position of the radiator upper cross member and remove cross member.
5. Unbolt the transmission auxiliary cooler and power steering cooler from the charge air cooler and set aside.
6. Remove the boost tubes from the charge air cooler.
7. Remove power steering reservoir retaining bolt, and set reservoir aside.
8. Remove the charge air cooler bolts.
NOTE: Care must be taken not to damage the charge air cooler fins and the fins of other ancillary cooler components.
9. Pivot the charge air cooler rearward and up to remove.
INSPECTION
Visually inspect the charge air cooler and plumbing for cracks, holes, loose clamps, or damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. Replace the charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge Air Cooler Tester Kit.
INSTALLATION
1. Position charge air cooler and install mounting bolts. Tighten bolts to 47 N·m (35 lb. ft).
2. Install the boost tubes to the charge air cooler . With the clamps in position, tighten the clamps to 11 N·m (95 in. lbs.)
3. Install the front fascia (Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION).
4. Connect the battery negative cable.
5. Start engine and check for leaks.