Intercooler: Service and Repair

Charge Air Cooling Circuit Cooler

Special tools, testers and auxiliary items required

• Hose Clamps Up to 25 mm Dia. (3094)

• Drip Tray (VAS 6208)

• Hose Clip Pliers (VAS 6362)

Removing

- Remove front bumper cover.

- On a vehicle with distance regulation, disconnect electrical connector - arrow - on distance regulation control module (J428).






• Ignore - 1 -.

- Remove the bolts - 3 - and remove the air guide.






- Remove the bolts - 4 - and the horn bracket; the electrical wires remain connected.

- Remove the bolts - 2 - and - 5 - and the headlamp bracket.

- Remove the nuts - 1 - and - 6 - and remove the bumper.

- Remove the outside air temperature sensor (G17) - arrow - from its retainer.






- Remove the bolts - 1 - and - 2 - for the power steering cooling coil; the hydraulic hoses remain connected.

- Remove the left and right air guides from the radiator.

- Place (VAS 6208) under engine.

- Loosen the hose clamps - arrow -, then clamp off the coolant hose with the (3094) and remove the hose.







Refrigerant can cause serious personal injury.

• Do not open the air conditioning refrigerant circuit.

- Disconnect the connector - 1 -.






- Remove the bolts - arrows -.


Risk of damage to condenser and refrigerant lines and hoses.

• Do not stretch, kink or bend refrigerant lines and hoses.

- Tip the condenser with the lines connected forward.

- Remove the charge air cooling circuit cooler.

- Secure the condenser with the bolts.

Installing

Install in reverse order of removal. Note the following:

• Tightening specifications, refer to => [ Radiator ] Radiator.

• If there are small impressions on the fins. Refer to => [ Coolers and Condensers ] Coolers and Condensers.

• Secure all hose connections with hose clamps appropriate for the model.

- Install the condenser.

- Install the power steering cooling coil.

- Install the bracket for the horns.

- Install the front bumper.

- Fill with coolant => [ Filling ] Procedures.

• If the charge air cooling circuit cooler was replaced, then it will be necessary to change all the coolant.

- If the distance regulation control module (J428) was removed, an adjustment must be made after reinstallation.