GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 2004 🢒 Isuzu MD F-Series 🢒 Engine 🢒 Engine Controls - 7.8L 🢒 Charge Air Cooler Replacement

Removal Procedure
  1. Tilt the cab. Refer to Cab Tilting .
  2. Remove the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection .

    3. Object Number: 1253435 Size: SH
  3. Remove the clamps from the charge air intake hose.
  4. Remove the hose from the intake manifold inlet pipe and the charge air cooler.

    5. Object Number: 1253441 Size: SH
  5. Remove the clamps from the air inlet hose.
  6. Remove the hose from the charge air cooler and the turbocharger inlet.

    7. Object Number: 1253433 Size: SH
  7. Remove the mounting bolts from the charger air cooler to the radiator.
  8. Remove the charger air cooler from the radiator.

Installation Procedure

    Object Number: 1253433 Size: SH
  1. Install the charge air cooler to the radiator.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the mounting bolts to the radiator.

    3. Tighten
    Tighten the bolts to 45 N·m (33 lb ft).


    Object Number: 1253441 Size: SH
  3. Install the hose assembly to the charger air cooler and the turbocharger inlet.
  4. Install the hose assembly to the charge air cooler and the intake manifold inlet pipe.
  5. Tighten the hose clamps.

    6. Tighten
    Tighten the hose clamps to 6 N·m (53 lb in).

  6. Install the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection .
  7. Lower the cab.