Cooling Module - Vehicles With: Non-Electric Vehicles (G2861046): Removal
- Make sure the engine cooling system is cool prior to doing this procedure.
- Be prepared to collect escaping coolant fluids.
- 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.
- 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.
- Disconnect the 12 V system.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT .
- Raise and support the vehicle on a suitable 2 post lift.
Refer to: JACKING AND LIFTING .
- Evacuate the Air Conditioning (A/C) system.
Refer to: AIR CONDITIONING SYSTEM RECOVERY, EVACUATION AND CHARGING .
- Partially drain the engine cooling system.
Refer to: COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING .
- With assistance, remove the front bumper.
Refer to: FRONT BUMPER .
- Remove the engine undershield.
Refer to: ENGINE UNDERSHIELD .
- Remove the 5 bolts.
- Remove the front bumper insulator.
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CAUTION: Take extra care when releasing the clips.
- Disconnect the electrical connector.
- Release the 2 wiring harness clips.
- Remove the 2 fasteners.
- Remove the upper active grille air shutter at the 3 clips.
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CAUTION: Take extra care when releasing the clips.
- Disconnect the electrical connector.
- Release the wiring harness clip.
- Remove the 8 screws.
- Remove the lower air deflector at the 3 clips.
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CAUTION: Take extra care when releasing the clips.
- Disconnect the electrical connector.
- Remove the 3 screws.
- Release the 2 clips.
- Remove the lower active grille air shutter as illustrated.
Release the 2 wiring harness clips.
Release the electrical connector clip.
- Remove the 4 bolts.
- Remove the cooling module protector.
- Remove the intake air resonator.
Refer to: INTAKE AIR RESONATOR .
Release the coolant pipe clip.
Remove the dirty air duct at the 7 clips.
Disconnect the 2 electrical connectors.
Disconnect the 2 lower coolant hoses from the radiator.
- Remove the bolt.
- Release the 8 coolant hose clips.
Disconnect the electrical connector.
- 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.
- Disconnect the 2 upper coolant hoses from the radiator.
- Disconnect the coolant pipe from the radiator.
Disconnect the upper coolant hose from the charge air radiator.
- 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.
- Release the electrical connector clip.
- Release the 2 wiring harness clips.
- Remove the front right wheel arch liner.
Refer to: FRONT WHEEL ARCH LINER .
Disconnect the 2 coolant hoses from the auxiliary radiator.
- Remove the 4 bolts.
- Remove the auxiliary radiator.
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CAUTION:
- Make sure that the cooling module is properly supported before removing the bolts.
- Use a suitable tool to support the cooling module.
- Remove the 4 bolts.
- Remove the 2 lower mounting brackets.
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CAUTION:
- Make sure that the cooling module is properly supported before removing the bolts.
- Use a suitable tool to support the cooling module.
- Remove the 4 bolts.
- Remove the 2 cooling module support brackets.
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WARNING: This step requires the aid of another technician.CAUTION: Take extra care not to damage the component.
With assistance, remove the cooling module.