Engine/Transmission (1998.5 - 2002) charge air cooler removal ?

[Jed]

According to the dodge service manual the charge air cooler should come out the front after removing the front bumper and condenser. However, the intake/outlet horns will not fit around the radiator. So, while it drains I thought I would ask what the correct proceedure is for removing the cooler. I guess I could have posted this question before I started but that would have made too much sense.

The only thing I can see is to take out the radiator or at least get it up a few inches so the intake and outlet horns will clear it.

Thanks in advance for any wise words.

 

[HeavyHauler]

You don't have to remove the condenser or the radiator to just remove the aftercooler. Just unbolt it the condenser from the aftercooler and swing it towards the passenger side. Support it with a stool or something.



Just remove the front bumper and the charge air cooler should pull up and out from the front. It isn't necessary to remove the radiator if you are just taking out the aftercooler.

 

[Jed]

I can see swinging the condenser out of the way, but even with the condenser unbolted there was no way to get the air cooler out without removing the radiator. I do not know if something changed or what. Anyway it is out.

thanks

 

[HoleshotHolset]

Afer you remove the bumper, you can CAREFULLY lift the radiator up (with hoses still attached... ) with a couple of pry bars in the mounting tabs and remove the intercooler. That's how I swapped in a 24-valve IC into my '94 12-valve.



Matt