3500 4x4 Pickup L6-359 5.9L DSL Turbo (1996)
Intercooler: Service and Repair
REMOVAL
1. Remove the grille.
Condenser And Intercooler
2. Remove the front support bracket.
3. If the vehicle is equipped with air conditioning, remove the condenser as follows:
a. Discharge the air conditioning system.
b. Remove the bolt from the sealing plate.
c. Remove the nuts holding the condenser to the charge air cooler (intercooler). Lift the condenser and sealing plate assembly away from the
charge air cooler (intercooler).
Intercooler Ducts
4. Remove the inlet and outlet ducts from the charge air cooler (intercooler).
WARNING: IF THE ENGINE WAS JUST TURNED OFF, THE INTAKE AND OUTLET DUCTS MAY BE HOT.
5. Remove the charge air cooler (intercooler) bolts. Pivot the charge air cooler (intercooler) forward and up to remove.
INSTALLATION
1. Position the charge air cooler (intercooler). Install the bolts and tighten to 2 Nm (17 in lb) torque.
2. Install the inlet and outlet ducts to the charge air cooler (intercooler). With the clamps in position, tighten the clamp nut to 8 Nm (72 in lb) torque.
3. If the vehicle is equipped with air conditioning, install the condenser as follows:
a. Position the condenser and sealing plate assembly onto the charge air cooler (intercooler) studs. Install the nuts and tighten.
b. Connect the halves of the sealing plate. Install the bolt and tighten.
c. Charge the air conditioning system.
4. Install the front support bracket. Install and tighten the bolts.
5. Install the grille.