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Charge Air Cooler

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position charge air cooler to mounting location.
    NOTE: When lowering radiator, make sure lower radiator pins engage properly through charge air cooler tabs. See Fig 1.
    Fig 1: Charge Air Cooler Locating Tab
    GC0019365Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOCATING TAB
    2 - LOWER RADIATOR SUPPORT CROSSMEMBER
    3 - RADIATOR MOUNT BUSHING
    4 - CHARGE AIR COOLER
  2. Install radiator (Refer to COOLING/ENGINE/RADIATOR - INSTALLATION) .
  3. Install fasteners attaching charge air cooler to radiator. Torque fasteners to 8 N.m (70 in. lbs.).
  4. Install radiator fan (Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .
  5. Connect charge air cooler hoses. Tighten hose clamps to 1.7 N.m (15 in. lbs.).
  6. Install front bumper (Refer to FRAME & BUMPERS/BUMPERS/FRONT BUMPER REINFORCEMENT - INSTALLATION) .
  7. Install front bumper fascia (Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION) .
  8. Install upper radiator closure panel and center brace (Refer to BODY/EXTERIOR/RADIATOR CLOSURE PANEL - INSTALLATION) .
  9. Install grille (Refer to BODY/EXTERIOR/GRILLE - INSTALLATION) .
  10. Install battery tray and battery (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION) .
  11. Connect positive battery cable.
  12. Connect negative battery cable.
  13. Install air cleaner housing
  14. Fill cooling system, (Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) .
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