Charge air cooler — removal and installation (Defender 2007+)

Removing

1. Disconnect the wire "masses" from the battery.

For more information, see the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mount and Wires, General Procedures).

2. Remove the grille.

For more information, see the chapter: Radiator grille (501-08 Exterior finish, Removal and installation).

3. Remove the top cooling fan shroud. Release 6 clips.



4. Remove the hood latch panel.

For more information, refer to the chapter: Bonnet lock panel (501-27 Repairs of sheet metal elements of the front end, Removal and installation).

5.

NOTE: Right side shown, left side similar.

Remove two o-rings.



6.

NOTE: Right side shown, left side similar.

Remove the two aftercooler brackets. Turn out 4 bolts.



7.

CAUTION: Plug all openings. Use new plugs.

NOTE: Right side shown, left side similar.

Disconnect the charge air cooler inlet and outlet hoses.



8. Remove the charge air cooler. Turn out two bolts.

Installation

1. Install the elements in the reverse order of disassembly. Tighten (tightening torque 20 Nm).




2.

NOTE: Remove and discard plugs.

Tighten (tightening torque 3 Nm).



3. Tighten (tightening torque 9 Nm).



4. Connect the wire "masses" to the battery.

For more information, see the chapter: Connecting the Battery (414-01 Battery, Battery Mount and Wires, General Procedures).