Cooling Module: Removal

WARNING:

Make sure the engine cooling system is cool prior to doing this procedure.

Be prepared to collect escaping coolant fluids.

CAUTION:

The desiccant bag need only be changed under the following circumstances: There is dirt in the refrigerant circuit (For example: compressor seizure), the system is leaking and refrigerant has been lost to atmosphere, or the refrigerant circuit has been open more than 24 hours, due to repair.

Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.
Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.

NOTE:

This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

This procedure contains illustrations showing certain components removed to provide extra clarity.

Raise and support the vehicle on a suitable 2 post lift.
Refer to: LIFTING .
Disconnect the 12 V system.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT .
Evacuate the Air Conditioning (A/C) system.
Refer to: AIR CONDITIONING SYSTEM RECOVERY, EVACUATION AND CHARGING .
Remove the front bumper.
Refer to: FRONT BUMPER - INGENIUM I4 2.0L DIESEL/INGENIUM I4 2.0L PETROL/TDV6 3.0L DIESEL/V6 S/C 3.0L PETROL .
Drain the engine cooling system.
Refer to: COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING .
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- Release the coolant pipe clip.
- Release the 4 clips and remove the dirty air duct.
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- Remove the 4 bolts.
- Remove the 2 upper radiator support brackets.
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Disconnect the 2 electrical connectors.
CAUTION: Be prepared to collect escaping coolant.

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- Disconnect the electrical connector and release the wiring harness clip.
- Disconnect the 2 coolant hoses.
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- Remove the bolt.
- Release the 8 coolant hose clips.
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Disconnect the electrical connector.
CAUTION: Be prepared to collect escaping coolant.

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- Disconnect the lower coolant hose from the charge air radiator.
- Release the coolant hose clip.
- Remove the bolt.
- Release the charge air cooler coolant pump.
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- Disconnect the 2 upper coolant hoses from the radiator.
- Disconnect the coolant pipe from the radiator.
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Disconnect the upper coolant hose from the charge air radiator.
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- Remove the bolt.
- Remove the nut.
- Release the 2 A/C pipes from the A/C condenser.
- Remove and discard the 4 O-ring seals.
CAUTION: Make sure that the cooling module is supported for this step.

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- Remove the 2 bolts.
- Remove the left cooling module bracket.
CAUTION: Make sure that the cooling module is supported for this step.

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- Remove the 2 bolts.
- Remove the right cooling module bracket.

CAUTION: This step must be completed with the assistance of another technician.

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Remove the cooling module.