Charge Air Cooler

Charge Air Cooler

Special tools, testers and auxiliary items required

• Engine Bung Set (VAS 6122)

Removing






- Remove the radiator. Refer to => [ Radiator ] Radiator.

- Remove front bumper cover.

- Disconnect the connector - 1 - on the outside air temperature sensor (G17).

- Remove the bolts - 2 - on the left and right charge air cooler air ducts.

- Disengage the air ducts - 3 -. To do this they must slide forward slightly.

- Tilt the air ducts to the left side of the vehicle and remove them behind the bumper.


Refrigerant can cause serious personal injury.

• Do not open the air conditioning refrigerant circuit.


Risk of damaging refrigerant lines and hoses.

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

- Remove the bolt on the refrigerant line retaining clamp near the longitudinal member.

- Remove the condenser bolts - 2 -.






- Remove the bolts - 1 - on the charge air cooler.

- Tilt the charge air cooler back slightly.

- Remove the bolt on the refrigerant line bracket at the lower right of the charge air cooler.






- Tilt the condenser forward into the opening on the lock carrier.

- Disengage the charge air cooler upward from the lock carrier and remove it downward diagonally.

Installing

Install in reverse order of removal. Note the following:

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

• Replace the seal.

• Secure all hose connections with hose clamps of the same type as those equipped by the factory.

- Install the radiator. Refer to => [ Radiator ] Radiator.

- Install front bumper.

- Air guides, installing with connector. Refer to => [ Hose Connections with Connector Couplings, Assembling ] Service and Repair

- Fill with coolant => [ Filling ] Service and Repair.