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CHARGE AIR COOLER AND PLUMBING
DESCRIPTION
The charge air system consists of the charge air
cooler piping, charge air cooler and intake air grid
heater.
The charge air cooler is a heat exchanger that uses
air flow from vehicle motion to dissipate heat from the
intake air. As the turbocharger increases air pressure,
the air temperature increases. Lowering the intake air
temperature increases engine efficiency and power.
OPERATION
Intake air is drawn through the air cleaner and into the
turbocharger compressor housing. Pressurized air
from the turbocharger then flows forward through the
charge air cooler located in front of the radiator. From
the charge air cooler the air flows back into the intake
manifold.
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DIAGNOSIS AND TESTING
CHARGE AIR COOLER SYSTEM - LEAKS
Low turbocharger boost pressure and low engine per-
formance can be caused by leaks in the charge air
cooler or plumbing. Fuel staining on the exhaust man-
ifold can also be an indication that there are leaks in
the air system. The followingprocedure outlines how
to check for leaks in the charge air cooler system.
This procedure can also be used to check for leaks in
the wastegate signal line or the wastegate canister.
1. Loosen clamp and remove air inlet hose from tur-
bocharger.
2. Insert Special Tool 9022 Adapter into the turbo-
charger inlet. Tighten tool clamp to 8 Nꞏm (72 in.
lbs.).
CAUTION: Do not apply more than 138 kPa (20
psi) air pressure to the charge air cooler system,
severe damage to the charge air cooler system
may occur.
3. Connect a regulated air supply to air fitting on Tool
9022 Adapter. Set air pressure to a Maximum of
138 kPa (20 psi).
4. Using soapy water check the rubber sleeves, charge air cooler and intakemanifold for leaks.
5. Using soapy water check for leaks at the wastegate signal line, wastegate canister and wastegate command
valve.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
1. Disconnect the battery negative cables.
2. Discharge the A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - STANDARD
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 auxiliary cooler (Refer to
7 - COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
4. Remove intake air tubing from the charge air
cooler.
5. Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
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CLEANING
CAUTION: Do not use caustic cleaners to clean the charge air cooler. Damageto the charge air cooler will
result.
NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced.
1. If the engine experiences a turbocharger failure or any other situationwhere oil or debris get into the charge air
cooler, the charge air cooler must be cleaned internally.
2. Position the charge air cooler so the inlet and outlet tubes are vertical.
3. Flush the cooler internally with solvent in the direction opposite of normal air flow.
4. Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris.
5. Continue flushing until all debris or oil are removed.
6. Rinse the cooler with hot soapy water to remove any remaining solvent.
7. Rinse thoroughly with clean water and blow dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears,
breaks, or other damage. Replace the charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge Air Cooler Tester Kit No.3824556. This kit is available through
Cummins
Service Products. Instructions are provided with the kit.
INSTALLATION
1. Position the charge air cooler. Install the bolts and
tighten to 2 Nꞏm (17 in. lbs.) torque.
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2. Install the air intake system tubes to the charge air
cooler. With the clamps in position, tighten the
clamps to 11 Nꞏm (95 in. lbs.) torque.
3. Install the transmission auxiliary cooler (if
equipped) (Refer to 7 - COOLING/TRANSMIS-
SION/TRANS COOLER - INSTALLATION).
4. Install the A/C condenser (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C CONDENSER - INSTALLATION).
Recharge A/C system (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
5. Connect the battery negative cables.
6. Start engine and check for boost system leaks.
Page 2173 of 5267
Page 2174 of 5267

FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRAMES & BUMPERS
SPECIFICATIONS
TORQUE .................................... 2
FRONT AIR DAM
REMOVAL ..................................... 3
INSTALLATION ................................ 3
FRONT BUMPER
REMOVAL ..................................... 4
INSTALLATION ................................ 4
FRONT FASCIA
REMOVAL ..................................... 5
INSTALLATION ................................ 6
REAR BUMPER
REMOVAL ..................................... 7
INSTALLATION ................................ 8
FASCIA-FRONT SRT-10
REMOVAL ..................................... 9
INSTALLATION ................................ 11
FASCIA-REAR SRT-10
REMOVAL .................................... 14
INSTALLATION ............................... 15
FRAME
WARNING
WARNINGS ................................ 17
STANDARD PROCEDURE
HYDROFORM FENDER RAIL REPAIR ........ 18REAR FRAME H-SECTION REPLACEMENT . . . 27
SPECIFICATIONS
WELD PROCESS ........................... 33
FRAME DIMENSIONS ....................... 34
TORQUE ................................... 45
FRONT CROSSMEMBER
REMOVAL .................................... 46
INSTALLATION ............................... 48
FRONT SKID PLATE
REMOVAL .................................... 50
INSTALLATION ............................... 51
FRONT TOW HOOK ASSEMBLY
REMOVAL .................................... 52
INSTALLATION ............................... 53
TRANSMISSION CROSSMEMBER
REMOVAL .................................... 54
INSTALLATION ............................... 56
TRAILER HITCH
REMOVAL .................................... 58
INSTALLATION ............................... 60
TRANSFER CASE SKID PLATE
REMOVAL .................................... 62
INSTALLATION ............................... 63
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FRAMES & BUMPERS
SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION Nꞏm Ft. Lbs.
Front bumper center bracket nuts 95 70
Front bumper stud plate nuts 95 70
License plate hitch reinforcement bolts 54 40
Rear bumper support bracket stud plate nuts 54 40
Rear bumper support bracket to hitch bolts 54 40
Rear bumper to hitch bolts 54 40
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FRONT AIR DAM
REMOVAL
1. Remove the two outboard screws.
2. Remove the three middle screws and remove the air dam.
INSTALLATION
1. Position the air dam onto the bumper and seat the carrot type fasteners fully.
2. Starting at the center screw install the three middle screws.
3. Install the two outboard screws.