INTERCOOLER (w/o EGR Cooler) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01DYO3

      Remove the 3 bolts, 2 nuts and cover.

  3. REMOVE NO. 1 GAS FILTER


    1. A01DXTV

      Remove the bolt and filter.

  4. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A01DXVU

      Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  5. REMOVE CHARGE AIR COOLER ASSEMBLY


    1. A01E2UO

      Disconnect the diesel turbo IAT sensor connector.

    2. Loosen the 2 hose clamps of the No. 1 air hose.

    3. A01DXAO

      Loosen the 2 hose clamps of the No. 2 air hose.

    4. A01DYHX

      Remove the 4 bolts and CAC.

    5. A01E1NN

      Using a 22 mm deep socket wrench, remove the IAT sensor.

      Tech Tips

      Replace the IAT sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the IAT sensor each time the CAC is replaced.

    6. A01E0PG

      Remove the 4 bolts, intake air connector and gasket.