Engine - No Start Condition In Cold Weather

21 12 01

March 12, 2012

2025464 *Supersedes T.B. V211106 dated September 06, 2011 to clarify warranty table information and include additional model year.*





Vehicle Information

Condition

Frozen Charge Air Cooler - Engine Will Not Start

Engine will not start after standing in cold weather below 0°C (32°F), MIL may be illuminated with various induction and/or boost system faults stored in ECM.

Technical Background

Moisture from the intake air condenses and collects in the charge air cooler. At cold temperatures this moisture can freeze causing blockage of the intake air system.

Production Solution

None.

Service

Install revised charge air cooler kit P/N 1K0 198 803B to avoid the formation of this moisture in the boost system.

Procedure

^ Lock carrier in service position. See Repair Manual Group 50 in ElsaWeb.

^ Separate A/C condenser from charge air cooler.

^ Remove radiator and radiator fan assembly.

^ Remove the original charge air cooler (item 3 in figure 1) from the vehicle.





^ Remove the lower charge pressure hoses (items 4 and 16 in figure 1) and clean of any moisture or sludge. See Repair Manual Group 21, Turbocharger/G-Charger, Description and Operation, Component Overview, in ElsaWeb.

^ Remove cold side charge air pipe (item 12 in figure 1) and pressure hose to throttle valve (item 7 in figure 1).

^ Separate the A/C condenser from the charge air cooler.

^ Remove the radiator and radiator fan assembly.

^ Separate the charge air pressure sensor -G31-- from cold side charge air pipe.

^ Install charge air pressure sensor -G31- from kit to cold side charge air pipe.

^ Loosely fit the pressure hose with new temperature switch to the cold side charge air pipe.

Tip:

By loosely installing pressure hose with switch to cold side charge air pipe allows for "wiggle room" when reinstalling

^ Install the cold side charge air pipe (item 12 in figure 1) and connect the charge air pressure sensor -G31- electrical connector.





^ Note the vacuum hose routing on the temperature switch (figure 2).





^ Route vacuum overlay harness as seen in figures 3 and 4.





^ Cut ventilation hose to air cleaner where indicated in figure 5.





^ Install splice as indicated in figure 6.

Tip:

Note the white tracer on the vacuum hose in figure 6.





^ Cut vacuum source hose where indicated in figure 7, and install splice.

^ Install the revised charge air cooler (item 3 in figure 1) with regulating flap and connect the regulating flap vacuum hose.

^ Re-assemble all charge air pipe connections.

^ Connect A/C condenser to charge air cooler using fasteners from kit, and install radiator with fan assembly.

^ Reassemble front carrier.

^ Re-aim headlights.

Warranty








Please verify engine code for accurate warranty table selection.








Please verify engine code for accurate warranty table selection.





Required Parts and Tools

No Special Tools required.

Additional Information

All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.