Charge Air Cooler, Removing And Installing: Installing
Replace the seals, O-rings and self-locking bolts after removing.
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.
-- 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-.
Holding the supercharger housing perpendicular in the :VAS6095A makes it easier to install and remove the charge air cooler.
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 in direction of -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.
-- As soon as it is possible, install the two bolts loosely by hand to help guide the charge air cooler.
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.
Installation is performed in reverse order of removal, while noting 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 .
-- Install the charge air pressure sensor. Refer to CHARGE AIR PRESSURE SENSOR - G31- / -G447-, REMOVING AND INSTALLING .
-- Check the supercharger for leaks. Refer to SUPERCHARGER, CHECKING FOR LEAKS .