Intercooler: Service and Repair

Charge Air Cooler

Removing

- Remove the noise insulation.

- Remove the bumper cover.

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

- Remove the right charge air hose clamps - arrows - and hose.





- Remove the fan shroud. Refer to => [ Fan Shroud ] Fan Shroud.

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

The condenser 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 point on the template - arrow - with a punch.

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

- Drill or cut the hold to 16 mm.

- Remove the bolt - arrow - for the condenser pipes.





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





• The 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 condenser bolts - arrows - from the charge air cooler.





- Secure the condenser to the lock carrier with cable ties.

- Remove the charge air cooler downward.

Installing

Installation is performed in the reverse order of removal, noting the following:

• 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 lubricated. Refer to => [ Hose Connections with Connector Couplings, Assembling ] Hose Connections With Connection Couplings, Assembly.