2014 Jeep Wrangler JK Factory Service Manual 09 - Engine, 2.8L Diesel

COOLER and HOSES, Charge Air

REMOVAL

WARNING:

If the engine was just turned off, the air intake system tubes may be hot.



NOTE:

When servicing the Air Charge Cooler and/or Turbocharger, the Air Charger Hose (orange) seal located between the Air Charge Hose and Turbocharger must be replaced.


NOTE:

Note the location of the rubber charge air 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.

WARNING:

Review the warnings and cautions for this system before performing the procedure. Failure to follow these instructions may result in serious injury or death.

  1. Disconnect the battery negative cable.

    2.  
  2. Raise and support the vehicle.

    3.  
  3. Remove the wheelhouse splash shield, (Refer to 23 - Body/Exterior/SHIELD, Splash - Removal) .

    4.  
  4. Remove the lower radiator seal push pins.

    5.  
  5. Remove the lower radiator hose to fan shroud retainers (1).

    6.  
  6. Remove the lower electric cooling fan mounting bolts.

    7.  
  7. Drain the coolant from the radiator, (Refer to 07 - Cooling - Standard Procedure) .

    8.  
  8. Remove the lower radiator hose (2).

    9.  
  9. Lower the vehicle.

    10.  
  10. Remove the grille, (Refer to 23 - Body/Exterior/GRILLE - Removal) .

    11.  
  11. Recover the refrigerant from the refrigerant system (Refer to 24 - Heating and Air Conditioning/Plumbing - Standard Procedure) .

    12.  
  12. Remove the air filter housing assembly, (Refer to 09 - Engine/Air Intake System/BODY, Air Cleaner - Removal) .

    13.  
  13. Remove the viscous fan, cooling fan and fan shroud as an assembly, (Refer to 07 - Cooling/Engine/FAN, Cooling - Removal) .

    14.  
  14. Remove the upper radiator hose.

    15.  
  15. Remove the nuts (3 and 5) that secure the A/C discharge line (2) and A/C liquid line (4) to the A/C condenser (1).

    16.  
  16. Disconnect the A/C discharge and liquid lines from the A/C condenser and remove and discard the O-ring seals and gaskets.

    17.  
  17. Install plugs into, or tape over the opened refrigerant line fittings and condenser ports.

    18.  
  18. Remove the hoses from the charge air cooler (1).

    19.  
  19. Remove the radiator mounting bolts.

    NOTE:

    Care must be taken not to damage the charge air cooler fins and the fins of other ancillary cooler components.


    20.  
  20. Remove the radiator, A/C condenser and charge air cooler as an assembly.

    21.  
  21. Remove the charge air cooler to condenser bolts and separate the charge air cooler (1).

    22.  

INSTALLATION

NOTE:

When servicing the Air Charge Cooler and/or Turbocharger, the Air Charger Hose (orange) seal located between the Air Charge Hose and Turbocharger must be replaced.

  1. Install the charge air cooler to the A/C condenser/radiator assembly. Tighten the bolts to 10 N·m (89 in. lbs.).

    NOTE:

    Care must be taken not to damage the charge air cooler fins and the fins of other ancillary cooler components.


    2.  
  2. Position the radiator, A/C condenser and charge air cooler into the vehicle as an assembly.

    3.  
  3. Install the radiator mounting bolts. Tighten the bolts to 9 N·m (81 in. lbs.).

    4.  
  4. Install the hoses to the charge air cooler (1). Tighten the clamps to 11 N·m (95 in. lbs.).

    5.  
  5. Remove the tape or plugs from the opened refrigerant line fittings and condenser ports.

    6.  
  6. Lubricate a new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

    7.  
  7. Connect the A/C discharge line (2) and the A/C liquid line (4) to the A/C condenser (1). Install the retaining nuts (3 and 5). Tighten the nuts to 23 N·m (17 ft. lbs.).

    8.  
  8. Install the upper radiator hose.

    9.  
  9. Install the viscous fan, cooling fan and fan shroud as an assembly (Refer to 07 - Cooling/Engine/FAN, Cooling - Installation) .

    10.  
  10. Install the air filter housing assembly (Refer to 09 - Engine/Air Intake System/BODY, Air Cleaner - Installation) .

    11.  
  11. Charge the refrigerant system (Refer to 24 - Heating and Air Conditioning/Plumbing - Standard Procedure) .

    12.  
  12. Install the grille, (Refer to 23 - Body/Exterior/GRILLE - Installation) .

    13.  
  13. Raise and support the vehicle (Refer to 04 - Vehicle Quick Reference/Hoisting/Standard Procedure) .

    14.  
  14. Install the lower radiator hose (2).

    15.  
  15. Install the lower electric cooling fan bolts. Tighten the bolts to 6 N·m (53 in. lbs.).

    16.  
  16. Install the lower radiator hose to fan shroud retainers (1).

    17.  
  17. Install the lower radiator seal push pins.

    18.  
  18. Install the wheelhouse splash shield, (Refer to 23 - Body/Exterior/SHIELD, Splash - Installation)

    19.  
  19. Lower the vehicle.

    20.  
  20. Fill the cooling system, (Refer to 07 - Cooling - Standard Procedure) .

    21.  
  21. Connect the battery negative cable.

    22.  
  22. Start engine and check for leaks.

    23.