Radiator / Charge Air Cooler (CAC), Replacement
Radiator / charge air cooler (CAC), replacement
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 from the charge air cooler (CAC) on the left-hand side (turbocharged engines only). If necessary, use a hot air gun to make removal easier
- Remove the screws for the radiator unit on the front cover plate.
Remove
- the two upper screws holding the radiator unit together
- the expansion tank cap.
Block the upper radiator hose with lock grip pliers
Work under the car
Remove
- the air baffles
- the lower oil cooler hose from the radiator unit (automatics only)
Note! Collect the oil from the oil cooler in a container.
- the screw for the mounting for the cable duct for engine wiring at the front edge of the sub-frame.
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 from above
- Remove the upper radiator hose. Place it to one side. Seal the openings.
Work under the car
- Disconnect the connector from the receiver drier and the cable from the holder
- 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 radiator unit.
- The following 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
- Replace the radiator / charge air cooler (CAC).
Installation
Installing the radiator and charge air cooler (CAC)
- Hold the radiator unit and secure the hose from the expansion tank to the radiator
- Install the connector from the receiver drier and the cable from the holder.
- 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.
- Install the lower screws to assemble the radiator unit. Tighten the screws. Tighten to 10 Nm
- Remove the tie straps
- Check that the radiator unit is against the rubber seal
- Tighten the radiator unit 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 radiator unit (automatic gearboxes only).
Work from above
Install
- the upper radiator hose. Remove the lock grip pliers
- the charge air pipe to the charge air cooler (CAC) on the left-hand side (turbocharged engines only).
- Install the upper screws to assemble the radiator unit. Tighten the screws
- Tighten to 10 Nm.
- Install the screws for the radiator unit on the front cover plate
- Tighten to 10 Nm
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.