Remove charge air cooler

WARNING: Working on 12 V electrical system
Risk of short circuits! Risk of fire!

Make sure that there is no charger connected to the jump start terminal in the engine compartment
Detach battery ground lead from battery
For auxiliary batteries: Detach battery minus cables from all auxiliary batteries

NOTE: RISK OF DAMAGE
Damage to battery terminal, the safety battery terminal or the intelligent battery sensor (IBS)
Damaged battery terminals can lead to malfunctions or vehicle electrical system faults

Detach battery terminal from battery pole. Do not pry off using a tool

NOTE: TECHNICAL INFORMATION
When the engine is stopped after the completion of trip, it may be necessary to run the electric fan. In rare cases, operation of the electric fan can last up to 11 min. This protects the components. In this case, replacing the electric fan will not remedy the problem!

Preliminary work

Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to REMOVING THE FRONT SPOILER .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THE FRONT BOTTOM SIDE COVER .
Refer to REMOVING THE RIGHT HAND FRONT BOTTOM SIDE COVER .
Refer to PARTIALLY RELEASING THE ENGINE OIL COOLER .
Refer to REMOVING THE LEFT AND RIGHT FRONT UNDERSHIELD .
Refer to REMOVING THRUST FIELD .
Refer to REMOVING THE FRONT-END STRUT .
Refer to REMOVING THE LEFT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
Refer to REMOVING THE CLEAN AIR PIPE FOR CYLINDERS 1 TO 3 .
Refer to REMOVING SEAL FOR FRONT HOOD .
Refer to REMOVING THE COVER FOR THE CENTER ENGINE COMPARTMENT .
Refer to REMOVING UPPER CROSS CONNECTION .
Refer to REMOVING THE REAR TOP CROSS CONNECTION .
Refer to REMOVING THE RIGHT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
Refer to DRAINING THE COOLANT FOR THE HIGH-TEMPERATURE COOLANT CIRCUIT .
Refer to REMOVING THE FAN COWL .
Refer to REMOVING SUSPENSION STRUT BRACE .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING THE COVER FOR THE DME CONTROL UNIT .
Refer to REMOVING THE DME CONTROL UNIT .
Refer to REMOVING THE INTEGRATED SUPPLY MODULE (PDM) PARTIALLY .
Refer to REMOVING THE CONTROL UNIT HOLDER .
Refer to DRAIN THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
Refer to REMOVING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .

Bolts of the charge air cooler with collector

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A Charge air cooler with manifold

1 - Screws

NOTE: RISK OF DAMAGE
Damage to wires when disconnecting connectors and plug connections
Sheared wires can cause a short circuit

Do not pull on wires when disconnecting connectors and plug connections

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations

NOTE: TECHNICAL INFORMATION
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head

Loosen screws (1)

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Loosen screws (1)
Feed out the charge air crossing (2) and place to one side

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Release nut (1)
Guide out the electrical auxiliary coolant pump (2) and set it aside

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Release the holder (1) from the electrical auxiliary coolant pump (2)

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Unlock plug connection (1) and disconnect

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Unlock the clamp (1) and engage it in this position

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Unlock the clamp (1)
Detach charge air hose (2)

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Unlock the locks (arrows)
Remove the wiring harness section (1) and put to one side

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Unlock plug connection (1) and disconnect
Unlock the locks (2)
Detach the tank vent line with pressure sensor (3)

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Release tank vent line (1) from clamps (2)

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Unlock the lock (1)
Remove the wiring harness section (2) and put to one side

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Release nut (1)
Guide out tank vent line (3) from holders (2) and keep it aside

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Loosen clamp (1)

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Unlock plug connection (1) and disconnect
Release clamps (2)

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Loosen screws (1)
Guide out and remove holder (2)

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Unlock and remove the coolant line (1)

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Unlock and remove the coolant line (1)

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Unlock coolant lines (1) and pull off
Unlock and detach the tank vent line (2)

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Unlock plug connection (1) and disconnect it from throttle valve (2)

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Release clamps (1) from charge air cooler (2) in the marked area

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Release the screws in the sequence (7) to (1)
Guide out and remove charge air cooler (A) carefully

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