Install charge air cooler
Bolts of the charge air cooler with collector
A Charge air cooler with manifold
1 - Screws
7
NOTE:
RISK OF DAMAGE
Improper routing of cables and wiring harnesses
Trapped, crushed or damaged cables may cause short circuits and malfunctions
Improper routing of cables and wiring harnesses
Trapped, crushed or damaged cables may cause short circuits and malfunctions
- Route all cables without abrasions, do not trap and crush
NOTE:
TECHNICAL INFORMATION
Make sure that the connections are locked correctly. The locks must engage audibly
Make sure that the connections are locked correctly. The locks must engage audibly
NOTE:
TECHNICAL INFORMATION
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head
- Replace the seals (1)
Parts: Seals
- Check the rubber mount (1) for a correct fit on the charge air coolerNOTE: Schematic diagram is for example purposes. Some parts may differ in certain details
- Clean contact surface (1)
- Ensure that charge air cooler (1) fits correctly on the bottom holder (2) during installation
- Insert and position the charge air cooler (A)
- Tighten the screws in the sequence (1) to (7)
TIGHTENING TORQUE SPECIFICATIONS
| Charge air cooler on cylinder head | ||
| M6 | tightening torque | 10 Nm |
- Secure clamps (1) to charge air cooler (2) in the marked area
- Connect connector (1) to throttle valve (2) and lock it
The connector (1) must engage audibly
- Connect and lock the tank vent line (2)
The tank vent line (2) must engage audibly
- Connect and lock the coolant lines (1)
The coolant lines (1) must engage audibly
- Connect and lock coolant line (1)
The coolant line (1) must engage audibly
- Connect and lock coolant line (1)
The coolant line (1) must engage audibly
- Insert and install the holder (2)
- Tighten the screws (1)
TIGHTENING TORQUE SPECIFICATIONS
| Holder to charge air cooler | ||
| 6x18 screw | Tightening torque | 5.5 Nm |
- Secure clamps (2)
- Connect connectors (1) and lock
The connector (1) must engage audibly
- Secure the clamp (1)
- Guide the tank vent line (3) into the holders (2) and connect it to the charge air cooler
- Tighten nut (1)
TIGHTENING TORQUE SPECIFICATIONS
| Tank vent line to charge air cooler | ||
| Nut | Tightening torque | 4 Nm |
- Insert and install the wiring harness section (2). The lock (1) must engage audibly
- Secure the tank ventilation line (1) to the clamp (2)
- Connect the tank vent line to pressure sensor (3)
- Ensure that all locks (2) engage audibly
- Connect connectors (1) and lock
The connector (1) must engage audibly
- Guide in the wiring harness section (1) and install
The locks (arrows) must engage audibly
- Ensure that the guide sleeves (1) are present and have been installed correctly
- Ensure that the guide sleeves (1) are present and have been installed correctly
- Check seal (1) for damage, replace if necessary
Replacing the damaged seal
NOTE:
TECHNICAL INFORMATION
Use of sharp or pointy tools for installation or removal is prohibited
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
- Replace gasket
Parts: Gasket
- Install the seal dry without lubricant or mounting agentNOTE: TECHNICAL INFORMATION
Incorrect assembly is possible. Ensure correct installation position - 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)
- Connect and lock charge air hose (2)
The clamp (1) must engage audibly
- Connect connectors (1) and lock
The connector (1) must engage audibly
- Attach holder (1) to the electrical auxiliary coolant pump (2)
- Feed in and install the electrical auxiliary coolant pump (2)
- Tighten nut (1)
TIGHTENING TORQUE SPECIFICATIONS
| Electric coolant pump to holder | ||
| M6 | tightening torque | 8 Nm |
- Insert the charge air crossing (2) and position it
- Tighten the screws (1)
TIGHTENING TORQUE SPECIFICATIONS
| Charge air duct on spacers | ||
| M6x25 screw | tightening torque | 10 Nm |
- Tighten the screws (1)
TIGHTENING TORQUE SPECIFICATIONS
| Charge air duct on spacers | ||
| M6x25 screw | tightening torque | 10 Nm |
Follow-up work
- Refer to INSTALLING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
- Refer to CONNECT THE COOLANT LINES FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
- Refer to SECURING THE ENGINE OIL COOLER .
- Refer to INSTALL FAN COWL .
- Refer to CONNECTING THE COOLANT LINE TO THE RADIATOR .
- Refer to INSTALLING THE RIGHT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
- Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
- Refer to INSTALLING UPPER CROSS CONNECTION .
- Refer to INSTALLING THE CENTER ENGINE COMPARTMENT COVER .
- Refer to INSTALLING THE FRONT HOOD SEAL .
- Refer to INSTALLING THE INTAKE FILTER HOUSING ON THE LEFT (FRONT-END STRUT REMOVED) .
- Refer to INSTALLING THE CLEAN AIR PIPE FOR CYLINDERS 1 TO 3 .
- Refer to INSTALLING THE CONTROL UNIT HOLDER .
- Refer to PARTIALLY INSTALLING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
- Refer to INSTALLING THE DME CONTROL UNIT .
- Refer to INSTALLING THE COVER FOR THE DME CONTROL UNIT .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to INSTALLING THE STRUT BRACE .
- Refer to INSTALLING THE FRONT-END STRUT .
- Refer to RECONNECTING ALL BATTERY GROUND LEADS .
- Refer to FILLING AND VENTING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
- Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .
- Refer to INSTALLING THE STIFFENING PLATE .
- Refer to INSTALLING THE LEFT AND RIGHT FRONT UNDERSHIELD .
- Refer to INSTALLING THE BOTTOM FRONT RIGHT SIDE COVER .
- Refer to INSTALLING BOTTOM FRONT COVER FROM THE SIDE .
- Refer to INSTALLING FRONT UNDERBODY PROTECTION .
- Refer to INSTALLING THE FRONT SPOILER .