Intercooler: Service and Repair

Charge Air Cooler

Removing

- Remove the noise insulation.

- Remove the bumper cover.

- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.

- Remove the charge air hoses - arrows -.






- Remove the fan shroud. Refer to => [ Fan Shroud and Fans ] Service and Repair.

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

The Air Conditioning (A/C) pipes are bolted to the right side of the charge air cooler. To remove the bolt, proceed as follows:

- Create a paper template with the specified dimensions.






- Position the template on the right front plastic support so it aligns with the top and left edges.






- Mark the cutting points on the template - arrow - with a punch.

- Drill a hole in the plastic support with a 5 mm drill bit.

- Drill or cut the hole to 16 mm.

- Remove the bolt - arrow - for the A/C pipe.






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






• The A/C condenser bolts are difficult to access. With the help of a second technician, lift the charge air cooler out of the lower mounts. Now the charge air cooler can be tilted back and forth and the bolts are accessible.

- Remove the A/C condenser bolts - arrows - from the charge air cooler.






- Attach the A/C condenser and the cable tie to the lock carrier.

- Remove the charge air cooler downward.

Installing

Install in reverse order of removal. Note the following:

• Charge air hose connections and charge air system hoses must be free of oil and grease before installing. On connector couplings, the seal and sealing surfaces must only be lightly oiled. Refer to => [ Charge Air Hose, Installing ] Charge Air Hose, Installing.