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Charge air cooler (B235R, B205L/R)

Charge air cooler (B235R, B205L/R)

To remove


1. Undo the hose clips on the charge air cooler inlet and outlet hoses.


2. Detach the charge air cooler's inlet charge air hose.

3. Raise the car.

4. Remove both the lower air shields.


5. Remove the charge air cooler's outlet charge air hose.


6. Detach the front edges of the wing liners from the bumper.

7. Unplug the fog light connectors.

8. Lower the car to the floor.

9. Remove the front grille.


10. Remove the RH and LH light clusters and headlamps.

11. Remove the wiper arms.

Detach the washer hose that is fastened to the bumper.

12. Unscrew the 2 bolts holding the bumper to the bumper member.


13. Remove the temperature sensor located in the centre of the bumper.

14. Lift off the bumper by pulling it forwards so that it clears the mountings in the wings and on the front.

15. Raise the car.

16. Remove the charge air cooler from the radiator member, 2 bolts.


17. Lift out the charge air cooler.


To fit


1. Lift the charge air cooler into position.

Note

Make sure that the temperature sensor's lead runs clear above the charge air cooler.



2. Bolt the charge air cooler to the radiator member, 2 bolts.

3. Connect the charge air cooler outlet hose.

4. Lower the car to the floor.

5. Connect the charge air cooler inlet hose and tighten the hose clip.

6. Tighten the hose clip on the charge air cooler's outlet hose.

7. Fit the temperature sensor.


8. Position the bumper.

Important

Make sure the mountings on the corners of the bumper are secured tightly to the body brackets.


Tighten the 2 retaining bolts.

Tightening torque: 39 Nm (29 lbf ft)

9. Fit the wiper arms and secure the washer hose to the bumper.


10. Fit the RH and LH headlamps and light clusters.

11. Lower the headlamp wiper arms.

12. Fit the front grille.

13. Raise the car.

14. Carefully bend the wing liners inside the edge of the bumper and fasten them in place.


15. Plug in the fog light connectors.

16. Make sure that the charge air cooler outlet hose is securely connected.

17. Fit the two lower air shields.


18. Lower the car to the floor.