Orlando

Charge Air Cooler Replacement - Diesel and LUJ with MT

1. Remove the battery cover. Refer to Battery Cover Replacement .
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
3. Remove the inlet air duct. Refer to Inlet Air Duct Replacement .
4. Remove the radiator air seal .



5. Disconnect the air conditioning refrigerant pressure sensor wiring harness plug from the air conditioning condenser.
6. Unclip the 2 radiator protector fenders (2) from the radiator (1).



7. If equipped, remove the 3 power steering fluid cooling loop pipe bracket hose clamp nuts (2, 4).
8. If equipped, remove the 3 hose clamps (5).
9. If equipped, remove the 2 power steering fluid cooling loop pipe bracket bolts (3, 6).
10. If equipped, remove the 2 power steering fluid cooling loop pipe brackets (1).



11. Remove the charge air cooler inlet hose (1) from the charge air cooler (2).



12. Remove the charge air cooler outlet hose (2) from the charge air cooler (1).




Note: Handle the cooling module with care.

13. Remove the condenser (3) from the charge air cooler (2) and secure with safety belts.
14. Remove the charge air cooler (2) in top direction from the radiator (1).

Note: Handle the cooling module with care.

1. Install the charge air cooler (2) to the radiator (1).
2. Remove the safety belts and install the condenser (3) to the charge air cooler (2).



3. Install the charge air cooler outlet hose (2) to the charge air cooler (1).



4. Install the charge air cooler inlet hose (1) to the charge air cooler (2).

Caution: Refer to Fastener Caution in the Preface section.




5. If equipped, install the 2 power steering fluid cooling loop pipe brackets (1).
6. If equipped, install the 2 power steering fluid cooling loop pipe bracket bolts (3, 6) and tighten to 9 N·m (80 lb in).
7. If equipped, install the 3 hose clamps (5).
8. If equipped, install the 3 power steering fluid cooling loop pipe bracket hose clamp nuts (2, 4) and tighten to 9 N·m (80 lb in).



9. Clip in the 2 radiator protector fenders (2) to the radiator (1).
10. Connect the air conditioning refrigerant pressure sensor wiring harness plug to the air conditioning condenser.
11. Install the radiator air seal .
12. Install the inlet air duct. Refer to Inlet Air Duct Replacement .
13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
14. Install the battery cover. Refer to Battery Cover Replacement .