For 1990-2009 cars only
- Remove the manifold sight shield. Refer to Intake Manifold Sight Shield Replacement.
- Remove the charge air coolant cap.
- Verify that coolant is visible near to top of the opening.
- Using a small funnel, slowly fill the charge air cooling system through the charge air coolant cap port with a 50/50 coolant mixture until the level is slightly below the charge air coolant cap port. Refer to Approximate Fluid Capacities.
- Ensure the charge air cooler cooling fill cap is installed in the proper orientation.
- Install the charge air coolant cap bolts and tighten to 10 N·m (89 lb in).
- Install the manifold sight shield. Refer to Intake Manifold Sight Shield Replacement.
Note: Make sure the intercooler system is cool and that the pump is not in the ON position.
Note: It is normal to have a very small pocket of air at the top of the system below the fill cap on a properly filled charge air cooling system.
Note: Use a 50/50 mixture of DEX-COOL® antifreeze and clean drinkable water.
Pour the coolant in very small amounts to avoid coolant spillage from the charge air coolant cap port or from funnel.
| • | The alignment boss (1) is at the rear of the charge air cooler manifold. |
| • | The alignment boss (2) is at the front of the charge air cooler cooling filling cap. |
Caution: Refer to Fastener Caution in the Preface section.
