Right Charge Air Water Cooler

REMOVAL 

1. Disconnect and isolate the negative battery cable.
2. Remove the left front lamp unit. Refer to UNIT, FRONT LAMP, REMOVAL AND INSTALLATION .
3. Drain the turbocharger cooling system. Refer to COOLING/STANDARD PROCEDURE .
4. Remove the right throttle body air inlet hose. Refer to COOLER AND HOSES, CHARGE AIR, REMOVAL AND INSTALLATION .
5. Remove the right side air supply tube support bracket from turbocharger to charge air water cooler. Refer to COOLER AND HOSES, CHARGE AIR, REMOVAL AND INSTALLATION .
6. Remove the right cold air intake tube. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .

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7. Remove the bolt (1) and the charge air water cooler coolant pump with hoses.

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8. Remove the bolts (1) securing multi-way coolant return pipe from the charge air water cooler to the triple pipe.

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9. Remove the bolt (1) and lower nut (1) securing the right charge air water cooler to the frame.

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10. Disconnect the inlet multi-way hose quick coupling (1) for the coolant pump to the pressure pump, on the pump side.

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11. Loosen the band (1) and disconnect the multi-way degassing hose of the supercharging air cooling system from the right charging air-water cooler.
12. Disconnect the water inlet hose quick connector (2) to the right charger air-water cooler.
13. Disconnect the water outlet hose quick connector (3) to the right charger air water cooler.

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14. Disconnect the air temperature/pressure sensor wire harness connector (1a).
15. Remove the upper bolts (1b) securing the right charger air water cooler to the support frame.

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16. Disconnect the right charger air water cooler from engine cooling hose (1).

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17. Remove the right charger air water cooler (1).

INSTALLATION 

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1. Install the right charge air water cooler (1) in position.

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2. Connect the right charger air water cooler from engine cooling hose (1).

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3. Connect the air temperature/pressure sensor wire harness connector (1a).
4. Install the upper screw (1b) securing the right charge air-water cooler to the support frame and securely tighten.

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5. Connect the water outlet hose quick connector (1) to the right charger air water cooler.
6. Connect the water inlet hose quick connector (2) to the right charger air-water cooler.
7. Connect the multi-way degassing hose (3) of the supercharging air cooling system from the right charging air-water cooler and tighten the band.

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8. Connect the inlet multi-way hose quick coupling (1) for the coolant pump to the pressure pump, on the pump side.

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9. Install the right lower charger air water cooler bolt to the support frame and securely tighten.

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10. Install the bolts (1) securing multi-way coolant return pipe to the charge air water cooler to the triple pipe and securely tighten.

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11. Install the charge air water cooler coolant pump with hoses and securely the bolt (1).
12. Install the right cold air intake tube. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
13. Install the right side air supply tube support bracket from turbocharger to charge air water cooler. Refer to COOLER AND HOSES, CHARGE AIR, REMOVAL AND INSTALLATION .
14. Install the right throttle body air inlet hose. Refer to COOLER AND HOSES, CHARGE AIR, REMOVAL AND INSTALLATION .
15. Fill the turbocharger cooling system. Refer to COOLING/STANDARD PROCEDURE .
16. Install the left front lamp unit. Refer to UNIT, FRONT LAMP, REMOVAL AND INSTALLATION .
17. Connect the negative battery cable.
18. Adjust and align the head lamp. Refer to STANDARD PROCEDURE .