Installing the right-hand charge air cooler

• Replace hose (1).

  Parts:  Hose

• Position hose (1) with hose clamps (2) as shown.
• Replace hose (5).

  Parts:  Hose

• Position the hose (5) and the hose clamp (3) (diameter 60-80 mm) at the top.
• Ensure that the hose clamp at the top (3) in the area of threaded connection is aligned with the screw on boost pressure sensor.

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• Position hose clamp (4) on hose (5) (diameter of 77-84 mm) at the bottom.
• Ensure that the hose clamp at the bottom (4) in the area of the threaded connection is aligned with the rubber mount on the charge air cooler.
• Guide in and position charge air cooler (1) at the bottom. 

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• Tighten the hose clamps (1) on the charge air cooler (2).

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• Position the connecting plate (2) between the charge air coolers.
• Tighten down screws (1).

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• Connect connectors (2) and lock.
• Tighten down screw (1).

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• Snap line (1) into holder (2).

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• Position the centering pin (1) on the holder downwards in lug (2) on the charge air cooler.

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• Engage the holder (1) on the charge air cooler.

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• Carefully position the line (1).
• Connect connectors (2) and lock.
• Connect the line (1) and lock.

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• Connect hose (2).

  The retaining clip (1) must snap-in audibly.

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• Connect the line (1) and lock.

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• Tighten hose clamp (3).

• Tighten hose clamp (4).

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• Position holder (2).
• Tighten down screw (1).

• Slide the hose (2) onto the studs of the charge air cooler.
• Replace the hose clamp and the hose.

  Parts:  Hose clamp with hose

• Tighten the hose clamp (3).

• Feed the hose (1) into the holder on the charge air cooler (4).

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• Slide the hose (2) onto the studs of the charge air cooler.
• Replace the hose clamp and the hose.

  Parts:  Hose clamp with hose

• Tighten the hose clamp (3).
• Thread in the hose (1) in the holder on the charge air cooler (4).

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• Attach the coolant lines (2).

The retaining clip (1) must snap-in audibly.

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Follow-up work 

• Refer to INSTALLING OIL FILLER NECK .
• Refer to CLOSING THE COOLANT PUMPS .
• Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
• Refer to INSTALLING THE WHEEL ARCH COVER ON THE FRONT LEFT AND BOTTOM RIGHT .
• Refer to INSTALLING FAN COWL WITH ELECTRIC MOTOR .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING RIGHT INTAKE SILENCER HOUSING .
• Refer to INSTALLING LEFT INTAKE SILENCER HOUSING .
• Refer to INSTALLING FRONT CROSS CONNECTION .
• Refer to TIGHTENING THE LEFT FRONT-END STRUT .
• Refer to TIGHTENING THE FRONT-END STRUT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE LEFT .
• Installing the cover panel of the master DME control unit.

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  • Position the cover of the master DME control unit (1)
  • Engage the cover panel of the master DME control unit (1) downwards with the clamps (2) and the guide pins (3) in the carrier plate of the DME.
• Refer to INSTALLING THE COVER PANEL OF THE SLAVE DME CONTROL UNIT .