Charge Air Cooler, Removing And Installing: Installing

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Fig 1: Installing Charge Air Cooler

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Tightening specifications. Refer to OVERVIEW - CHARGE AIR SYSTEM .

NOTE:

Replace the seals, O-rings and the self-locking screws.

Always clean the threaded holes inside the supercharger housing with a thread tap before assembling.

-- Check the seal -5- on the charge air cooler -4-.

The seal must not be cracked or damaged.

-- Slide the seal -1- onto the charge air cooler.

-- Insert the O-ring -2- into the opening in the supercharger housing -3-.

-- Coat the sealing surface -arrow A- and the charge air cooler seal -arrow B- -1- with engine oil.

Fig 2: Identifying Sealing Surface -Arrow A- And Charge Air Cooler Seal -Arrow B-

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-- Coat the inner sealing surface inside the supercharger housing with engine oil.

-- Make sure the seals are opposite the openings in the supercharger housing when installing the charge air cooler -arrows-.

Fig 3: Ensuring Seals Are Opposite Openings In Supercharger Housing When Installing Charge Air Cooler -Arrows-

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NOTE:

Holding the supercharger housing perpendicular in the Engine and Gearbox Bracket VAS6095A makes it easier to install and remove the charge air cooler.

Fig 4: Installing Charge Air Cooler

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CAUTION:

Danger of causing damage to the charge air cooler.

Install the charge air cooler by hand only.

-- Install the charge air cooler all the way into the supercharger housing by hand -arrow A-. When doing this, let the front of the charge air cooler slide into the hole -arrow B- inside the supercharger housing.

-- Manually guide the charge air cooler by hand through the supercharger housing openings -arrows-, if necessary.

Fig 5: Identifying Supercharger Openings -Arrows-

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-- As soon as it is possible, install the two bolts loosely by hand to help guide the charge air cooler.

CAUTION:

Danger of causing damage to the charge air cooler.

The charge air cooler may not be installed by using the bolts.
Install the charge air cooler by hand only until there is maximum 1 mm between the sealing flange and the seal and the supercharger housing. Only then should the bolts be tightened as follows:

-- Tighten the bolts for the left -1 and 2- and right -3 and 4- charge air coolers in a diagonal sequence and in small steps.

Fig 6: Identifying Bolts For Left -1 To 2- And Right -3 To 4- Charge Air Coolers

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Install in reverse order of removal. Note the following:

-- Install the coolant pipes to the supercharger. Refer to COMPRESSOR COOLANT PIPES, REMOVING AND INSTALLING .

-- Install the Throttle Valve Control Module -J338-. Refer to Throttle Valve Control Module -J338-, REMOVING AND INSTALLING .

-- Check the supercharger for leaks. Refer to SUPERCHARGER, CHECKING FOR LEAKS .