Charge Air Cooler
Charge air cooler (CAC), replacing
Note! As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Removing the battery lead and draining the air conditioning (A/C) system
Disconnect the battery negative lead. See: Battery, disconnecting Battery Disconnecting.
Drain the air conditioning (A/C) system. See Refrigerant, draining Refrigerant, Draining.
Removing the skidplate
Remove the 6 screws.
Lift up and slide the plate forward.
Remove the splash guard.
Note! There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.
Draining coolant
Block the lower hose with lock grip pliers.
Install a hose on the nipple at the radiator.
Feed the hose down to a container.
Open the nipple and drain off the coolant.
Removing the cable duct and air duct
Remove the screw for the cable duct. Place the cable duct on the sub-frame.
Pull the air duct from the clips on the sub-frame.
Removing the oil cooler hoses
Only applies to vehicles with automatic transmissions:
Remove the lower oil cooler hose from the air conditioning (A/C) aggregate.
Plug the openings in the hose and radiator.
Note! Collect the oil from the oil cooler in a container.
Lower the vehicle. Remove the upper oil cooler hose from the air conditioning (A/C) aggregate.
Plug the openings in the hose and radiator.
Removing the charge air pipe/hose
Disconnect the charge air pipe from the charge air cooler (CAC) on the left-hand side. If necessary, use a hot air gun to facilitate removal.
Remove the clamp. Remove the charge air hose on the right-hand side from the charge air cooler (CAC).
Removing the upper coolant hoses
Remove:
- the evacuation hose from the expansion tank and the clip mounting
- the upper radiator hose.
Removing the right-hand headlamp
Pull the locking plate straight up.
Separate the connector.
Remove the headlamp.
Removing the air conditioning (A/C) pipe
Remove from the left-hand side:
- screw
- the air conditioning (A/C) pipe.
Seal the openings on the pipe and condenser.
Remove from the right-hand side:
- the connector
Raise the car
Remove:
- screw
- the air conditioning (A/C) pipe.
Seal the openings on the pipe and receiver.
Hint: Pull down and hang up the left-hand pipe so that the hose is positioned above the sub-frame.
Removing the lower engine coolant hose
Slacken off the hose clamp. Remove the hose from the radiator.
Fold the hose out of the way.
Removing the radiator assembly
Note! Two people are required for this procedure.
Hold up the air conditioning aggregate and slacken off the two mounting screws.
Carefully lower the air conditioning aggregate.
Note! Ensure that no hoses are trapped when removing the air conditioning aggregate.
Removing the engine cooling fan (FC)
Remove:
- the screws
- the evacuation hose from the clip mountings
- the engine cooling fan (FC).
Removing the radiator
Remove:
- the screws
- the air conditioning aggregate.
Removing the charge air cooler (CAC)
Lift out the charge air cooler (CAC).
Installing the charge air cooler (CAC)
Position the charge air cooler (CAC) over the condenser.
Installing the radiator
Position the radiator over the condenser and the charge air cooler (CAC).
Install the screws. Tighten to 10 Nm.
Installing the engine coolant fan (FC)
Install:
- the engine cooling fan (FC)
- the screws. Tighten to 10 Nm
- the evacuation hose in the clip mountings.
Installing the cooler unit
Note! Two people are required for this procedure.
Lift up the air conditioning aggregate. Install the two mounting screws. Tighten to 24 Nm.
Note! Ensure that the air conditioning aggregate is positioned correctly in the locating pins on top of the aggregate.
Note! Ensure that no hoses are trapped when installing the air conditioning aggregate.
Installing the lower engine coolant hose
Install the hose. Tighten the clamp.
Remove the lock grip pliers.
Installing the charge air pipe/hose
Install:
- the charge air hose on the right-hand side
- the charge air pipe on the left-hand side.
Tighten the clamps.
Installing the air conditioning (A/C) pipe
Hint: Lubricate the O-rings. Use compressor oil.
Install on the right-hand side:
- the air conditioning (A/C) pipe. Use a new O-ring.
- the screw. Tighten to 10 Nm.
Lower the vehicle.
Install the connector on the receiver.
Install on the left-hand side:
- the air conditioning (A/C) pipe. Use a new O-ring.
- the screw. Tighten to 24 Nm.
Vacuum pump the air conditioning (A/C) system. See Vacuum pumping Vacuum Pumping.
Installing the right-hand headlamp
Install:
- the connector
- the headlamp
- the locking plate.
Installing the upper engine coolant hoses
Install:
- the upper radiator hose.
- the evacuation hose on the expansion tank and clip mounting.
Installing the oil cooler hoses
Only applies to vehicles with automatic transmissions:
Install the upper oil cooler hose.
Use a new O-ring.
Raise the car
Install the lower oil cooler hose.
Use a new O-ring.
Installing the cable duct and air duct
Position the cable duct.
Install the screw. Tighten to 10 Nm.
Install the air duct using the clip on the sub-frame.
Installing the skid plate
Move the skid plate up into the bumper cover.
Press forward until the mounting brackets enter the sub-frame.
Install the screws. Tighten to 50 Nm.
Finishing
Fill the air conditioning (A/C) system. See Refrigerant, filling Refrigerant, Filling.
Check for leaks. See Leak tracing, fluorescent tracing agent/UV lamp Leak Tracing, Fluorescent Tracing Agent/UV Lamp or Leak tracing, electronic leak tracer Leak Tracing, Electronic Leak Tracer.
Install the battery lead.
Top up the coolant.
Install the cap on the expansion tank.
Run the engine until the thermostat has opened.
Stop the engine. Top up if necessary.
Check for leaks.