Charge Air Cooler

Removing

NOTE:

The following removal and installation procedure is for the left charge air cooler.

-- On a vehicle with air suspension, activate vehicle lift mode. Refer to the appropriate service information .

-- Remove the front noise insulation -1-. Refer to the appropriate service information .

Fig 1: Identifying Front/Rear Noise Insulation

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-- Remove front bumper cover. Refer to the appropriate service information .

-- Pull the cover over the radiator -arrows-, to do this disconnect the lower coolant hose.

Fig 2: Cover Over The Radiator -Arrows-

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-- Remove the bolts -2, 4 and 5-.

Fig 3: Bolts -2, 4 And 5

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NOTE:

Ignore -1, 3 and 6-.

-- Remove the bolts -1, 2 and 4- and then pull the upper air duct pipe off the charge air cooler.

Fig 4: Bolts -1, 2 And 4-

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NOTE:

Ignore -3-.

-- Unclip the air duct -1- from the charge air cooler.

Fig 5: Air Duct -1-

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-- Remove the bolts and nuts -1, 2 and 3-.

Fig 6: Bolts And Nuts -1, 2 And 3-

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-- Open the clip -1- and remove the charge air cooler.

Fig 7: Clip -1-

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NOTE:

Ignore -2, 3 and 4- and -arrows-.

Installing

Install in reverse order of removal. Note the following:

For the correct tightening specifications, refer to CHARGE AIR COOLER, VEHICLES BUILT THROUGH 05.10 OVERVIEW .

NOTE:

If there are small impressions on the fins. Refer to COOLERS, CONDENSERS AND CHARGE AIR COOLERS .

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps appropriate for the model.

-- Install the air duct pipes with the connector coupling. Refer to Figure.

-- Install front bumper. Refer to the appropriate service information .

-- Install the noise insulation. Refer to the appropriate service information .

-- On a vehicle with air suspension, deactivate vehicle lift mode. Refer to the appropriate service information .