OPERATION
In take air is dra wn through t he air cleaner an d
into the tu rbocha rger compressor housing. Pressur-
ized air from the t urboch arger then flows forwar d
through the ch arge a ir cooler locat ed in front of the
radiator. Fr om th e cha rge air cooler th e air flows
back into the inta ke manifold.
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS
NOTE: Slight engine oil pooling in the charge air
inlet hose IS NOT premature turbocharger failure.
Slight pooling is the normal result of the breather
system. Test the air breather tube for normal oper-
ation by referring to the appropriate diagnostic
manual.
Low tu rbocha rger boost pressu re and low engine
performance ca n be cau sed by leaks in th e charge air
cooler or it’s plumbing. The following procedur e out-
lin es h ow to check for leaks in t he cha rge a ir cooler
system.
(1) Loosen cla mp and rem ove tu rbocha rger to air
inlet duct rubber sleeve from t urboch arger.
(2) In sert Special Tool 8442 Adapter in to t he rub-
ber sleeve. Tighten existing cla mp to 8 N·m (72
in.lbs.).
CAUTION: Do not apply more than 138 kpa (20 psi)
air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.
(3) Connect regulated air supply to a ir fitting on
Special Tool 8442 Adapt er. Set air pressur e to a Max-
imum of 138 kpa (20 psi).
(4) Usin g soapy water check the air inlet duct s,
rubber sleeves, charge air cooler and intake m anifold
for leaks.
REMOVAL
(1) Remove front bu mper.
(2) Remove hea dlamp assemblies.
(3) Remove front cross member togeth er wit h front
grille .
(4) Remove left a nd right radiat or trim (F ig. 3).
(5) Disconn ect cha rge air hoses a t charge air cooler
(Fig. 3).
(6) Disconn ect power st eering cooler loop fr om
charge air cooler (Fig. 3).
(7) Remove cha rge air cooler from radia tor assem-
bly (Fig. 3).
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If the engine experiences a turbocharger failur e
or any ot her situation wh ere oil or debris get into the
charge air cooler, the charge air cooler must be
clean ed int erna lly.
(2) Position the char ge air cooler so the in let and
outlet tubes are vertical.
(3) Flush th e cooler internally wit h solven t in the
direct ion opposite of normal air flow.
(4) Sh ake t he cooler an d lightly ta p on the en d
tanks with a rubber mallet t o dislodge t rapped
debris.
(5) Continue flu sh ing until all debr is or oil are
removed.
(6) Rinse the cooler wit h hot soapy wa ter to
remove an y remainin g solvent.
(7) Rinse thorough ly wit h clea n water a nd blow
dr y with compressed a ir.
Fig. 3 CHARGE AIR COOLER
1 - POWER STEERING COOLER LOOP
2 - CHARGE AIR HOSE
3 - CHARGE AIR COOLER HOSE
4 - CHARGE AIR COOLER
5 - LEFT RADIATOR TRIM PANEL
6 - RIGHT RADIATOR TRIM PANEL
VA EXHAUST SYSTEM 11 - 5
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