SERVICE MANUALMANIFOLDSSection 2Exhaust Manifold - (D, DT and DTI Engines)1.Remove Turbocharger (If equipped). Refer toSection 1.2.Remove stud nuts and washers securing theexhaust manifold to the cylinder head.3.Remove manifold and manifold gaskets.Disassemble Intercooler as Follows:1.Remove flange (1, Fig. 5a), gaskets (2) and "O"rings on the intercooler coolant inlet 3 and outlethoses (4).2.Remove the cover bolts (7) then remove thecover (8) and gasket (9).3.Remove the housing bolts (10) to disassemblethe core (Fig. 5b) from the housing (11).Figure 5a. - Intercooler Disassembly SightsAE Application Shown (Others Similar)1.Intercooler Water Flange2.Intercooler Flange Gasket3.Water Inlet Hose4.Water outlet Hose5.Outlet Hose Clamps6.Inlet Hose Clamp7.Intercooler Cover Bolts8.Intercooler Cover9.Intercooler Cover Gasket10.Intercooler, Housing Bolts11.Intercooler HousingFigure 5b. - Intercooler DisassemblyCGES-185-3PRINTED IN UNITED STATES OF AMERICAPage 5
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