Install charge air cooler

Bolts of the charge air cooler with collector 

Fig 1: Charge Air Cooler With Manifold Screws Tightening Sequence

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A Charge air cooler with manifold 

1-7 Screws 

• Replace the seals (1).

  Parts:  Seals

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• Check the rubber mount (1) for a correct fit on the charge air cooler.

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  NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
• Clean contact surface (1).

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• Insert and position the charge air cooler (1).
• Connect connectors (2) and lock.

  The connector (2) must engage audibly.

• Secure clamp (arrow).

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• Insert and position the charge air cooler (A).
• Tighten the screws in the sequence (1) to (7).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Charge air cooler on cylinder head
  M6	tightening torque  10 Nm

  Fig 2: Charge Air Cooler Screws Tightening Sequence

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• Connect and lock coolant line (1).

  The coolant line (1) must engage audibly.

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• Connect and lock the tank vent line (2).

  The tank ventilation line (2) must snap-in audibly.

• Connect and lock the coolant lines (1).

  The coolant lines (1) must engage audibly.

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• Position the coolant line (1) and secure the clamp (arrow).

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• Connect and lock coolant line (1).

  The coolant line (1) must engage audibly.

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• Connect and lock the tank vent line (1).

  The tank vent line (1) must engage audibly.

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• Guide in the wiring harness section (1) and install.

  The locks (arrows) must engage audibly.

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• Secure the clamps (arrows).
• Feed in and position holder (3).
• Tighten the screws (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Holder to charge air cooler
  Self-tapping screw M6	Tightening torque  5 Nm

• Connect connectors (1) and lock.

  The connector (1) must engage audibly.

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• Ensure that the guide sleeves (1) are present and have been installed correctly.

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• Ensure that the guide sleeves (1) are present and have been installed correctly.

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• Check seal (1) for damage, replace if necessary.

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  Replacing the damaged seal 

  NOTE: TECHNICAL INFORMATION 
  Use of sharp or pointy tools for installation or removal is prohibited.
• Remove damaged seal.
• Clean the gasket groove (1) with a dry cloth.

  The gasket groove (1) must be clean.

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• Replace gasket.

  Parts:  Gasket

• Install the seal dry without lubricant or mounting agent.
  NOTE: TECHNICAL INFORMATION 
  Incorrect assembly is possible. Ensure correct installation position.

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• Thread in seal and install.
• Make sure that the seal is installed correctly in the gasket groove (1).
• Make sure that the sealing lip (2) is directed to the inside as shown.
• Lock clamp (1).

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• Connect the charge air line (1) to the throttle valve (2) and lock it.

  The charge air line (1) must engage audibly.

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• Insert the charge air crossing (2) and position it.
• Tighten the screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Charge air duct on spacers
  M6x25 screw	tightening torque  10 Nm

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• Tighten the screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Charge air duct on spacers
  M6x25 screw	tightening torque  10 Nm

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Follow-up work 

• Refer to CONNECTING THE COOLANT LINE TO THE RADIATOR .
• Refer to INSTALLING FAN COWL .
• Refer to INSTALLING CONTROL UNIT BRACKET .
• Refer to INSTALLING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
• Refer to INSTALLING THE DME CONTROL UNIT .
• Refer to INSTALLING COVER OF THE DME CONTROL UNIT .
• Refer to INSTALLING THE LEFT AIR DUCT .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING INTAKE FILTER HOUSING .
• Refer to INSTALLING THE STRUT BRACE .
• Refer to INSTALLING THE SEAL FOR THE HOOD GASKET LEFT AND RIGHT .
• Refer to INSTALLING THE COVER PANEL OF THE ENGINE COMPARTMENT ON THE REAR LEFT AND RIGHT .
• Refer to INSTALLING FRONT-END STRUT ON LEFT AND RIGHT .
• Refer to INSTALLING FRONT CROSS CONNECTION .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT AND RIGHT .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to CONNECTING THE COOLANT HOSE TO THE AUXILIARY COOLANT RADIATOR .
• Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY ON THE LEFT .
• Refer to INSTALLING THE FRONT SECTION OF THE FRONT WHEEL ARCH COVER ON THE LEFT AND RIGHT .
• Refer to PARTIALLY INSTALLING BOTH FRONT WHEEL ARCH TRIMS .
• Refer to INSTALLING THE FRONT BOTTOM RIGHT WHEEL ARCH COVER .
• Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
• Refer to INSTALLING FRONT UNDERBODY PROTECTION .
• Refer to FILLING AND VENTING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
• Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .