1. Introduction
This manual provides essential information for the proper installation, operation, and maintenance of your TYC 18077 Charged Air Cooler. This component is designed as a direct OE replacement for 2016-2020 Chevrolet Malibu models, ensuring optimal cooling efficiency for your vehicle's turbocharged engine system.
The TYC Charged Air Cooler is engineered with construction similar to original equipment, featuring precise tube and cooling fin counts. Its tanks are molded from super heat-resistant, high-density polymer plastic, offering enhanced protection against extreme engine temperatures. Each unit undergoes rigorous leak-testing prior to shipment to guarantee consistent quality and performance.
2. Product Overview
The TYC 18077 Charged Air Cooler is a critical component in your vehicle's forced induction system, responsible for cooling compressed air from the turbocharger before it enters the engine. This process increases air density, leading to improved combustion efficiency and engine performance.
Key Features:
- Perfect Fit: Engineered for direct OE replacement, ensuring precise fitment and straightforward installation.
- Premium Quality: Constructed with premium-grade aluminum tubes and precision-folded, louvered aluminum fins for optimal cooling efficiency.
- Exceptional Performance: Features comparable tube and fin pitch to OE counterparts, producing similar airflow volume to meet or exceed original equipment performance standards.
- Proven Reliability: Subjected to rigorous, high-pressure cycling tests to ensure durability in high-pressure turbocharged vehicle environments.
Components Included:
- One (1) TYC Charged Air Cooler
Figure 2.1: Front view of the TYC 18077 Charged Air Cooler, showing the core and end tanks.
Figure 2.2: Side view of the TYC 18077 Charged Air Cooler, highlighting the fin structure.
Figure 2.3: Close-up view of one end of the TYC 18077 Charged Air Cooler, showing the connection port with a blue protective cap.
3. Setup and Installation
Installation of the TYC 18077 Charged Air Cooler should be performed by a qualified automotive technician or individuals with appropriate mechanical experience. Improper installation can lead to vehicle damage or personal injury.
General Installation Guidelines:
- Safety First: Ensure the vehicle is turned off, cooled down, and properly secured on a lift or jack stands. Disconnect the battery's negative terminal.
- Access: Gain access to the existing charged air cooler. This may involve removing the front bumper, grille, or other components depending on the vehicle model.
- Disconnect: Carefully disconnect all hoses, clamps, and mounting hardware attached to the old charged air cooler. Be mindful of any residual fluids or pressure.
- Removal: Remove the old charged air cooler from the vehicle.
- Inspection: Inspect the surrounding components, including hoses, clamps, and mounting points, for any signs of wear, damage, or corrosion. Replace any compromised parts as necessary.
- Installation of New Unit: Position the new TYC 18077 Charged Air Cooler into place. Ensure all mounting points align correctly.
- Connect: Reconnect all hoses and clamps securely. Ensure all connections are tight to prevent air leaks.
- Reassembly: Reinstall any removed vehicle components (bumper, grille, etc.) in reverse order of removal.
- Final Checks: Reconnect the battery. Start the vehicle and check for any leaks or unusual noises. Monitor engine performance and temperature.
Note: Always refer to your vehicle's specific service manual for detailed, model-specific installation procedures and torque specifications.
4. Operating Principles
The charged air cooler, also known as an intercooler, operates by reducing the temperature of the air compressed by the turbocharger before it enters the engine's intake manifold. When air is compressed, its temperature increases significantly. Hot air is less dense, which reduces engine power and efficiency.
The TYC 18077 Charged Air Cooler functions as an air-to-air heat exchanger. Hot, compressed air from the turbocharger flows through a series of internal passages (tubes) within the cooler. Ambient air, drawn in by the vehicle's movement or a dedicated fan, flows over external fins surrounding these passages. Heat transfers from the hot compressed air to the cooler ambient air, effectively lowering the temperature of the intake charge. This cooler, denser air allows the engine to produce more power and operate more efficiently, while also reducing the risk of pre-ignition (knocking).
5. Maintenance
While the TYC 18077 Charged Air Cooler is designed for durability and minimal maintenance, periodic inspection can help ensure its longevity and optimal performance.
Recommended Maintenance:
- Visual Inspection: Periodically inspect the external fins of the charged air cooler for any obstructions such as leaves, dirt, or road debris. Clean gently with compressed air or a soft brush if necessary. Avoid bending the fins.
- Hose and Clamp Check: Inspect all connecting hoses and clamps for cracks, wear, or looseness. Ensure all connections are secure to prevent boost leaks.
- Leak Detection: If you suspect a performance issue, a professional can perform a boost leak test to check for any leaks in the charged air system, including the intercooler.
- Damage Assessment: After any front-end collision or impact, inspect the charged air cooler for physical damage, such as dents or punctures, which can impair its function.
Regular vehicle servicing by a qualified technician should include checks of the charged air system components.
6. Troubleshooting
If you experience issues related to your vehicle's turbocharged system, the charged air cooler may be a contributing factor. Below are common symptoms and potential causes related to the intercooler.
Common Symptoms and Solutions:
| Symptom | Potential Cause | Action |
|---|---|---|
| Reduced Engine Power / Lag | Boost leak (cracked intercooler, loose hose, damaged clamp) | Inspect intercooler and hoses for cracks or loose connections. Perform a boost leak test. Replace damaged components. |
| Check Engine Light (CEL) with related codes (e.g., P0299 - Underboost) | Significant boost leak or internal blockage | Consult a professional for diagnostic scanning and system inspection. |
| Increased Fuel Consumption | Inefficient cooling leading to engine compensation | Check for external blockages on the intercooler fins. Ensure proper airflow. |
| Visible Damage to Intercooler | Physical impact or corrosion | Replace the charged air cooler if physical damage is present. |
If you are unable to diagnose or resolve an issue, it is highly recommended to seek assistance from a certified automotive technician.
7. Specifications
The following specifications pertain to the TYC 18077 Charged Air Cooler:
| Specification | Value |
|---|---|
| Manufacturer | TYC |
| Brand | TYC |
| Model | TYC 18077 Replacement Charged Air Cooler for CHEVROLET MALIBU |
| Item Weight | 5.58 pounds |
| Product Dimensions | 24 x 10 x 10 inches |
| Item Model Number | 18077 |
| Manufacturer Part Number | 18077 |
| OEM Part Number | 23336319 |
| ABPA Partslink Number | GM3012109 |
| Position | Front, Rear (Refers to general vehicle fitment, not cooler orientation) |
| Exterior | Machined |
| Date First Available | March 8, 2017 |
8. Warranty and Support
For information regarding the warranty coverage for your TYC 18077 Charged Air Cooler, please refer to the warranty documentation provided with your purchase or visit the official TYC website. Warranty terms and conditions may vary.
Customer Support:
If you have questions about the product, installation, or require technical assistance, please contact TYC customer support directly. You can typically find contact information on the manufacturer's official website or through the retailer where the product was purchased.
For additional resources and product information, you may visit the TYC Store on Amazon.
