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Charge Air Cooler Outlet Hose Replacement - LNP and Manual Transmission

1. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
2. Remove the battery tray. Refer to Battery Tray Replacement .
3. Remove the engine control module. Refer to Engine Control Module Replacement .
4. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement .
5. 5.Unclip the engine wiring harness retaining clip from the charge air cooler outlet front hose.



6. Remove the charge air cooler outlet front hose bracket bolt (2).
7. Loosen the charge air cooler outlet front hose to rear hose clip (4).
8. Detach the charge air cooler outlet front hose (1) along with the clamp (4) from the charge air cooler outlet rear hose (3).



9. Unclip the 2 wiring harness retaining clips from the charge air cooler outlet rear hose (2).
10. Place a suitable tool at the rebate (1) and rotate the lock ring anti-clockwise.
11. Detach the charge air cooler outlet rear hose (2) from the throttle body (3).
12. Remove the charge air cooler outlet rear hose (2).
13. Remove the front bumper fascia. Refer to Front Bumper Fascia Removal and Installation .



14. Unclip the charge air cooler outlet hose (1) from the charge air cooler.
15. Remove the charge air cooler outlet hose (1) downwards from the vehicle.

1. Position the charge air cooler outlet hose (1) to the vehicle.
2. Connect the charge air cooler outlet hose (1) to the charge air cooler.
3. Install the front bumper fascia. Refer to Front Bumper Fascia Removal and Installation .




Note: Make sure that the retaining ring is locked.

4. Install the charge air cooler outlet rear hose (2) to the throttle body (3).
5. Clip in the 2 wiring harness retaining clips to the charge air cooler outlet rear hose (2).



6. Install the charge air cooler outlet front hose (1) along with the clamp (4) to the charge air cooler outlet rear hose (3).

Caution: Refer to Fastener Caution in the Preface section.

7. Install the charge air cooler outlet front hose bracket bolt (2) and tighten to 9 N·m (80 lb in).
8. Tighten the charge air cooler outlet front hose to rear hose clip (4) to 4 N·m (35 lb in).
9. Clip in the engine wiring harness retaining clip to the charge air cooler outlet front hose.
10. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement .
11. Install the engine control module. Refer to Engine Control Module Replacement .
12. Install the battery tray. Refer to Battery Tray Replacement .
13. Install the engine sight shield. Refer to Engine Sight Shield Replacement .