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Charge Air Cooler Replacement - 1.4L LUH, LUJ - M32-6 MZ4

Removal Procedure
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
  3. Drain coolant fluid. Refer to Cooling System Draining and Filling .
  4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  5. Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement : 2.0L Diesel LNP → LDD, LUH, and LUJ → 1.6L LXT,L2W → 2.0L Diesel LLW → LDE, LLU, LXV, 2H0, and LUW .
  6. Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement : 2.0L Diesel LNP → LDD, LUH, and LUJ → 1.6L LXT,L2W → 2.0L Diesel LLW → LDE, LLU, LXV, 2H0, and LUW .
  7. Remove the charge air cooler inlet air hose from the charge air cooler. Refer to Charge Air Cooler Inlet Air Hose Replacement .
  8. Remove the charge air cooler outlet air hose from the charge air cooler. Refer to Charge Air Cooler Outlet Air Hose Replacement : Manual Gearbox .
  9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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  10. Remove the air conditioning evaporator hose (3) from condenser.
  11. Disconnect the air conditioning refrigerant pressure sensor wiring harness plug (2).
  12. Disconnect the engine coolant temperature sensor wiring harness plug (1).
  13. Lower the vehicle.

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  14. Remove the air conditioning compressor and condenser hose nut (1).
  15. Remove the air conditioning compressor and condenser hose (2).
  16. Unclip the engine coolant fan shroud from the radiator and hang it aside, using cable straps.
  17. Secure the radiator assembly with 2 straps.

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  18. Remove the 4 lower radiator bracket bolts (1).
  19. Remove the 2 lower radiator brackets (2).

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    Note: A second technician is required.

    Note: Do not remove the engine cooling fan shroud (1).

  20. Remove the 2 straps.
  21. Remove the radiator assembly (2).
  22. Unclip the radiator from the charge air cooler and the condenser.

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  23. Unclip the air conditioning condenser (2) from the charge air cooler (1).

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  24. Unclip the charge air cooler (2) from the radiator (1).

Installation Procedure

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  1. Clip the charge air cooler (2) to the radiator (1).

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  2. Clip the air conditioning condenser (2) to the charge air cooler (1).

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    Note: A second technician is required.

  3. Install the radiator assembly (2) to the engine cooling fan shroud (1) and secure it with 2 straps.

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  4. Install the 2 lower radiator brackets (2)

    5. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the 4 lower radiator bracket bolts (1) and tighten to 22 N·m (16 lb ft).
  6. Clip in the engine coolant fan shroud to the radiator.

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  7. Install the air conditioning compressor and condenser hose (2). Use a NEW seal ring.

    8. Install the air conditioning compressor and condenser hose nut (1) and tighten to 19 N·m (14 lb ft).


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  8. Install the air conditioning evaporator hose (3) to the condenser. Use a NEW seal ring.
  9. Tighten the air conditioning evaporator hose nut to 19 N·m (14 lb ft).
  10. Connect the air conditioning refrigerant pressure sensor wiring harness plug (2).
  11. Connect the engine coolant temperature sensor wiring harness plug (1).
  12. Lower the vehicle.
  13. Install the radiator inlet hose to the radiator. Refer to Radiator Inlet Hose Replacement : 2.0L Diesel LNP → LDD, LUH, and LUJ → 1.6L LXT,L2W → 2.0L Diesel LLW → LDE, LLU, LXV, 2H0, and LUW .
  14. Install the radiator outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement : 2.0L Diesel LNP → LDD, LUH, and LUJ → 1.6L LXT,L2W → 2.0L Diesel LLW → LDE, LLU, LXV, 2H0, and LUW .
  15. Install the charge air cooler inlet air hose to the charge air cooler. Refer to Charge Air Cooler Inlet Air Hose Replacement .
  16. Install the charge air cooler outlet air hose to the charge air cooler. Refer to Charge Air Cooler Outlet Air Hose Replacement : Manual Gearbox .
  17. Fill up the refrigerant. Refer to Refrigerant Recovery and Recharging .
  18. Fill up coolant fluid. Refer to Cooling System Draining and Filling .
  19. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
  20. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
   


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