Dodge dakota 2002 Service Manual page 1671

11 - 16 EXHAUST SYSTEM
CHARGE AIR COOLER AND PLUMBING (Continued)
(1) Disconnect the battery negative cables.
(2) Discharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (if A/C
equipped).
(3) Remove the transmission
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - REMOVAL).
(4) Remove the boost tubes from the charge air
cooler (Fig. 24).
(5) Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
Fig. 24 Air Intake System Tubes
1 - BOLT
2 - CHARGE AIR COOLER
3 - CLAMP
4 - BOOST TUBE
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
or any other situation where oil or debris get into the
charge air cooler, the charge air cooler must be
cleaned internally.
outlet tubes are vertical.
auxiliary cooler direction opposite of normal air flow.
tanks with a rubber mallet to dislodge trapped debris.
removed.
remove any remaining solvent.
dry with compressed air.
INSPECTION
holes, or damage. Inspect the tubes, fins, and welds
for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Air Cooler Tester Kit #3824556. This kit is available
through Cummins
are provided with the kit.
INSTALLATION
and tighten to 2 N·m (17 in. lbs.) torque.
charge air cooler. With the clamps in position, tighten
the clamps to 11 N·m (95 in. lbs.) torque.
equipped) (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - INSTALLATION).
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C CONDENSER - INSTALLATION). Recharge
A/C system (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(1) If the engine experiences a turbocharger failure
(2) Position the charge air cooler so the inlet and
(3) Flush the cooler internally with solvent in the
(4) Shake the cooler and lightly tap on the end
(5) Continue flushing until all debris or oil are
(6) Rinse the cooler with hot soapy water to
(7) Rinse thoroughly with clean water and blow
Visually inspect the charge air cooler for cracks,
Pressure test the charge air cooler, using Charge
Service Products. Instructions
(1) Position the charge air cooler. Install the bolts
(2) Install the air intake system tubes to the
(3) Install the transmission auxiliary cooler (if
(4) Install the A/C condenser (if A/C equipped) (Refer
(5) Connect the battery negative cables.
(6) Start engine and check for boost system leaks.
DR