Removal Procedure
- Disconnect the negative battery cable. Refer
to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Remove the air cleaner outlet duct. Refer to
Air Cleaner Outlet Duct Replacement
.
- Loosen the charged air cooler outlet duct clamp (1).
Important: Do not use a screwdriver or other tool to pry the hose loose. The hose cam be
torn or damaged. Loosen the hose by twisting.
- Remove the charged air cooler outlet duct.
- Loosen the charged air cooler inlet duct
to turbocharger clamp (1).
- Remove the charged air cooler inlet duct from the turbocharger.
- Remove the engine wiring harness. Refer to
Engine Wiring Harness Assembly Replacement
.
- Remove the water outlet tube. Refer to
Water Outlet Tube Replacement
in Engine Cooling.
- Remove the junction block to fuel injection
pump fuel feed pipe.
Installation Procedure
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the junction block to fuel injection pump fuel feed pipe.
Tighten
Tighten the fitting to 41 N·m (30 lb ft).
- Install the water outlet tube. Refer to
Water Outlet Tube Replacement
in Engine Cooling.
- Install the engine wiring harness. Refer
to
Engine Wiring Harness Assembly Replacement
.
- Install the charged air cooler inlet duct to the turbocharger.
- Align the mark on the duct (2) with the mark on the turbocharger.
- Position the clamp (1) as shown for proper clearance.
Tighten
Tighten the clamp to 6 N·m (53 lb in).
- Install the charged air cooler outlet duct
to the intake.
- Align the mark on the duct (3) with the mark on the turbocharger.
- Position the clamp (1) as shown for proper clearance.
Tighten
Tighten the clamp to 6 N·m (53 lb in).
- Install the air cleaner outlet duct. Refer to
Air Cleaner Outlet Duct Replacement
.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.