Charge Air Cooler: Installing

WARNING: This page is about a different car, the 2012 Audi S5, 2011 Audi S5, and 2010 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Installation Of Charge Air Cooler With Remove/Install Components

Courtesy of AUDI OF AMERICA, LLC

Tightening specifications, refer to CHARGE AIR COOLER OVERVIEW .

NOTE:

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

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-

Courtesy of AUDI OF AMERICA, LLC

-- 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 When Installing Charge Air Cooler -Arrows-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Holding the supercharger housing perpendicular in the VAS 6095 makes it easier to install and remove the charge air cooler.

Fig 4: Identifying Installation Of Charge Air Cooler

Courtesy of AUDI OF AMERICA, LLC

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-

Courtesy of AUDI OF AMERICA, LLC

-- As soon as it is possible, install the 2 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

Courtesy of AUDI OF AMERICA, LLC

Install in reverse order of removal paying attention to the following:

-- Install the coolant pipes to the supercharger. Refer to SUPERCHARGER COOLANT PIPES .

-- Install throttle valve control module -J338-. Refer to Removal and Installation .

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