Intercooler: Service and Repair

Replacing radiator/charge air cooler (CAC)

Special tools:
999 5972 FIXTURE 999 5972 Fixture

Removing radiator assembly





Applies to cars with air conditioning (A/C)
Drain A/C system according to Draining/vacuum pumping/filling with coolant and leak-finding Draining/Vacuum Pumping/Filling with Coolant and Leak-Finding.
Remove the condenser hoses at the compressor and at the drier.

Remove
- the negative battery cable. First read Battery, disconnecting Battery Disconnecting.
- air duct to control module box.
- air cleaner (ACL) housing intake pipe from connection above radiator. Twist the pipe up.
- The canister purge (CP) valve from mounting on the fan shroud.
- release wiring from fan shroud.
Lift out expansion tank hose from the holders on top of fan shroud.
Disconnect both engine cooling fan (FC) connectors.

Remove
- the charge air pipe over the engine.
- both screws holding fan shroud. Carefully lift engine cooling fan (FC).
- expansion tank cap.
Block upper radiator hose with lock grip pliers.




- the splash guard under the engine
- screw for engine wiring cable duct mounting at front edge of subframe.





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





Remove
- upper radiator hose. Put to one side
- expansion tank hose at tank. Disconnect hose from clip so that it comes with the radiator
- intake hose to and outlet hose from charge air cooler (CAC).

Hint: When disconnecting outlet hose it is easier if the connection is heated with hot air gun 115 82 84 around the terminal.





Remove
- drain hose and tighten nipple on radiator
- lower radiator hose. Place to one side and seal openings.
- container
Position a mobile jack with universal plate 999 5972 FIXTURE 999 5972 Fixture under the radiator assembly.
- both mounting screws
Hold the radiator assembly and carefully lower it.

Replacing water cooler/charge air cooler (CAC)




Place the air conditioning aggregate on a level surface.
Remove the four screws holding the air conditioning aggregate together.
Replace cooler unit/charge air cooler (CAC).
Assemble air conditioning aggregate with the four screws.

Installing cooler unit




Position the radiator assembly on the mobile jack's universal plate 999 5972 FIXTURE 999 5972 Fixture.
Hold cooler unit and carefully raise it into position in the bodywork.
Install both the mounting screws and tighten to 25 Nm .

Install
- lower radiator hose. Remove lock grip pliers
- screw for engine wiring cable duct mounting at front edge of subframe
- front splash guard and air baffles.





Install
- upper radiator hose. Remove lock grip pliers
- hose to expansion tank. Secure hose with clips
- the plastic pipe to the charge air cooler (CAC)
- the condenser hoses at the compressor and at the drier.

Installing engine coolant fan (FC)




Carefully lower the fan shroud and align it with the holes at the sides of the radiator.
Tighten both mounting screws.
Connect engine cooling fan (FC) connectors.
Install charge air pipe over engine.
Press hose down from expansion tank into holder on fan shroud.
Secure wiring with tie straps as before.
Press canister purge (CP) valve into holder on fan shroud.
Turn down air cleaner (ACL) intake manifold and locate against sleeve connector above air conditioning aggregate.
Connect the negative battery cable. First read Battery, disconnecting Battery Disconnecting.
Fill the AC system. See Draining/vacuum pumping/filling with coolant and leak-finding Draining/Vacuum Pumping/Filling with Coolant and Leak-Finding.

Fill coolant
Install expansion tank cap.
Run the engine until the thermostat has opened.
Stop engine and top up coolant if necessary.