CHARGE AIR COOLER REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

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1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the front bumper. (See FRONT BUMPER REMOVAL.) (See FRONT BUMPER INSTALLATION.)

3.  Remove in the order shown in the figure.

4.  Install in the reverse order of removal.

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1
Charge air cooler outlet pipe
2
Charge air cooler inlet pipe
(See Charge Air Cooler Inlet Pipe Installation Note.)
3
Charge air cooler
(See Charge Air Cooler Removal Note.)
(See Charge Air Cooler Installation Note.)
4
Protector (if equipped)

Charge Air Cooler Removal Note

1.  Disconnect the boost pressure sensor/boost air temperature sensor connector. (See BOOST PRESSURE SENSOR/BOOST AIR TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

2.  Remove the charge air cooler.

3.  Remove the boost pressure sensor/boost air temperature sensor. (See BOOST PRESSURE SENSOR/BOOST AIR TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)


Charge Air Cooler Installation Note

1.  Remove foreign matter on the O-ring seal surface of charge air cooler and in the pipe furrow O-ring (sand or dust).

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Note
•  The color is different between the O-ring on the charge air cooler outlet pipe side and the O-ring on the charge air cooler inlet pipe side. Verify the color before installing the O-ring.

2.  Align the O-ring projection with the pipe furrow and install the O-ring.

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Color of O-ring
Charge air cooler outlet pipe side: Blue color
Charge air cooler inlet pipe side: Black color

3.  Temporarily install the bolts and nuts shown in the figure.

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4.  Tighten the charge air cooler in the order shown in the figure.

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Charge Air Cooler Inlet Pipe Installation Note

1.  Clean the seal surface and furrow area of the charge air cooler air inlet pipe.

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2.  Degrease the seal surface of the pipe, and verify if there is foreign matter penetration or scratches.

•  If there is foreign matter penetration or scratches, replace the pipe.

3.  Apply engine oil to the seal surface of the pipe.

Note
•  Make sure that the installation direction of the charge air cooler hose is correct and verify the marking shown in the figures.
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4.  Align the pipe rib and connector groove positions, and install.

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5.  Insert the pipe connector completely into the connector.

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6.  Pull the pipe outward and verify that a click sound is heard.

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