Replacing the Radiator / Charge Air Cooler (CAC)

Replacing the radiator / charge air cooler (CAC)

Special tools:
999 5972 FIXTURE 999 5972 Fixture

Removal

Removing the radiator unit
Remove the engine cooling fan (FC) according to Engine cooling fan (FC), replacing Service and Repair.




Disconnect the charge air pipe for the charge air cooler (CAC) on the left-hand and right-hand sides. Fold the hoses out of the way.
Remove the screws for the cooler unit on the front cover plate





Remove:
- the two upper screws holding the air conditioning aggregate together
- the expansion tank cap.




Block the upper radiator hose with lock grip pliers.
Disconnect the hose from the radiator. Collect the coolant that flows out.

Work under the car





Remove:
- the air baffles
- the lower oil cooler hose from the cooler unit (automatics only). Protect the hose opening
Note! Collect the oil from the oil cooler in a container.

- the screw (1) for the cable harness on the front edge of the sub-frame.
Disconnect the connector from the condenser on the right side. Press the spring to disconnect the connector.

Drain the coolant
- Block the lower hose coolant hose with lock grip pliers
- Apply a hose on the nipple at the radiator
- Feed the hose down to a container
- Open the nipple and drain off the coolant.

Work under the car




Hang up the condenser using tie straps on the right-hand side in the pipe for the receiver drier and on the left-hand side in the pipe for the condenser.
Remove the lower screws holding the air conditioning aggregate.





Hint: The following step requires two people.

Disconnect the radiator and the charge air cooler (CAC) firstly from the left and then from the right-hand side by removing the two screws.
On the right-hand side, press the cable duct and the compressor hose towards the engine. At the same time release the radiator and charge air cooler (CAC) downwards on the right-hand side. Then release the radiator and charge air cooler (CAC) on the left-hand side. Ensure that the mounting for the radiator and charge air cooler (CAC) passes the AC pipe.
Disconnect the hose from the radiator to the expansion tank.
Remove the radiator / charge air cooler (CAC).

Installation

Installing the radiator and charge air cooler (CAC)
Hold the radiator unit. Secure the hose from the expansion tank to the radiator. Use a new clamp.
Check that the 2 plastic nuts are in position on the radiator.




Lift up the radiator and charge air cooler (CAC) on the left-hand side. Ensure that the mounting for the charge air cooler (CAC) passes above the AC pipe. Lift the right-hand side while pressing the cable duct and the compressor hose towards the engine.
Thread the screws for the radiator and charge air cooler (CAC) into the member.
Connect the connector to the right-hand side of the condenser.




Install the lower screws to assemble the air conditioning aggregate. Tighten the screws. Tighten to 10 Nm.
Remove the tie straps.
Check that the air conditioning aggregate is against the rubber seal. Secure.
Tighten the air conditioning aggregate to the member. Tighten to 25 Nm.
Install the lower radiator hose.
Remove the lock grip pliers.
Install the screw for the mounting for the engine wiring cable duct at the front edge of the sub-frame.
Install the lower oil cooler hose on the air conditioning aggregate (automatic transmissions only).
Lower the car.

Installing the screws for the air conditioning aggregate




Install the upper screws to assemble the air conditioning aggregate. Tighten the screws. Tighten to 10 Nm.




Install the screws for the air conditioning aggregate on the front cover plate. Tighten to 10 Nm.





Install:
- the charge air pipe on the left and right-hand sides of the radiator
- the upper radiator hose.

Installing the engine cooling fan (FC)
To install the engine cooling fan (FC), see Engine cooling fan (FC), replacing Service and Repair.

Topping 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.