Cooling Module - Vehicles With: PHEV (G2861047): Installation

WARNING: This page is about a different variant/trim than selected.

WARNING: This step requires the aid of another technician.

CAUTION: Take extra care not to damage the component.

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With assistance, install the cooling module.
CAUTION:
- Make sure that the cooling module is properly supported before installing the bolts.
- Use a suitable tool to support the cooling module.
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- Install the 2 cooling module support brackets.
- Install and tighten the 4 bolts.
  Torque : 9 Nm
CAUTION:
- Make sure that the cooling module is properly supported before installing the bolts.
- Use a suitable tool to support the cooling module.
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- Install the 2 cooling module lower mounting brackets.
- Install and tighten the 4 bolts.
  Torque : 9 Nm
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- Install the auxiliary radiator.
- Install and tighten the 4 bolts.
  Torque : 9 Nm
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Connect the 2 coolant hoses to the auxiliary radiator.
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- Install the 2 wiring harness clips.
- Install the electrical connector clip.
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Connect the left lower coolant hose to the radiator.
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- Reposition the cooling system swirl pot in the correct location.
- Install and tighten the bolt.
  Torque : 9 Nm
- Install the coolant hose clip.
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- Reposition the charge air cooler coolant pump in the correct location.
- Install and tighten the bolt.
  Torque : 9 Nm
- Connect the electrical connector to the charge air cooler coolant pump.
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- Connect the right lower coolant hose to the radiator.
- Install the 4 coolant hose clips.
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Connect the 2 electrical connectors.
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Install the dirty air duct at the 7 clips.
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Connect the 2 upper coolant hoses to the radiator.
Install the intake air resonator.
Refer to: INTAKE AIR RESONATOR .
CAUTION: Take extra care not to damage the component.

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- Install the coolant pipe.
- Connect the 2 coolant pipe connectors.
- Install the 2 coolant pipe clips.
CAUTION:
- Lubricate the new seals with clean refrigerant oil.
- Make sure that new O-ring seals are installed.
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- Lubricate and install the 4 new O-ring seals to the A/C pipes.
  Renew Part: Air conditioning pipes to condenser O-ring seals Quantity: 4 .
- Install the 2 A/C pipes to the A/C condenser.
- Install and tighten the nut and bolt.
  Torque : 20 Nm
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Connect the 2 coolant hoses to the charge air radiator.
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Connect the 2 coolant hoses to the PHEV battery coolant radiator.
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- Install the cooling module protector.
- Install and tighten the 4 bolts.
  Torque
  
  M12 bolt: 90 Nm
  
  M10 bolt: 45 Nm
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Install the electrical connector clip.
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Install the 2 wiring harness clips to the cooling module protector.
- Install the lower active grille air shutter at the 2 clips.
- Install and tighten the 3 screws.
  Torque : 7 Nm
- Connect the electrical connector to the lower active grille air shutter.
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- Install the lower air deflector at the 3 clips.
- Install and tighten the 8 screws.
  Torque : 7 Nm
- Install the wiring harness clip.
- Connect the electrical connector to the Cruise Control Module (CCM).
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- Install the upper active grille air shutter at the 3 clips.
- Install the 2 fasteners.
- Install the 2 wiring harness clips.
- Connect the electrical connector to the upper active grille air shutter.
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- Install the front bumper insulator.
- Install and tighten the 5 bolts.
  Torque : 7 Nm
Install the front right wheel arch liner.
Refer to: FRONT WHEEL ARCH LINER .
With assistance, install the front bumper.
Refer to: FRONT BUMPER .
Install the engine undershield.
Refer to: ENGINE UNDERSHIELD .
Connect the 12 V system.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT .
Fill the PHEV battery cooling system with the correct amount of coolant fluid.
Refer to: PHEV BATTERY COOLING SYSTEM DRAINING AND VACUUM FILLING .
Fill the engine cooling system with the correct amount of coolant fluid.
Refer to: COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING .
Recharge the A/C system.
Refer to: AIR CONDITIONING SYSTEM RECOVERY, EVACUATION AND CHARGING .
Calibrate the CCM .
Refer to: CRUISE CONTROL MODULE DYNAMIC CALIBRATION .