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 by carefully shifting to and fro. Do not pry off using a tool.

Preliminary work

Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to REMOVING THE TOP RIGHT AND LEFT COVER IN THE ENGINE COMPARTMENT .
Refer to REMOVING FRONT CROSS CONNECTION .
Refer to REMOVING THE LEFT AND RIGHT FRONT-END STRUT .
Refer to REMOVING THE ENGINE COMPARTMENT COVER PANEL IN THE REAR LEFT AND RIGHT .
Refer to REMOVING STAND FOR THE HOOD GASKET LEFT AND RIGHT .
Refer to REMOVING SUSPENSION STRUT BRACE .
Refer to REMOVING INTAKE SILENCER HOUSING .
Refer to REMOVING THE REAR TOP CROSS CONNECTION .
Refer to REMOVING THE LEFT-HAND AIR DUCT .
Refer to REMOVING THE COVER PANEL OF THE DME CONTROL UNIT .
Refer to REMOVING THE DME CONTROL UNIT .
Refer to REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
Refer to REMOVING CONTROL UNIT BRACKET .
Refer to REMOVING THE FRONT LEFT AND RIGHT WHEELS .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THE CENTER UNDERBODY PROTECTION .
Refer to REMOVING THE FRONT RIGHT LOWER WHEEL ARCH COVER
Refer to PARTIALLY REMOVING BOTH FRONT WHEEL ARCH TRIMS .
Refer to REMOVING THE FRONT SECTION OF THE FRONT WHEEL ARCH COVER ON THE LEFT AND RIGHT .
Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY ON THE RIGHT .
Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
Refer to REMOVING FAN COWL .
Refer to DRAINING THE COOLANT FOR THE HIGH-TEMPERATURE COOLANT CIRCUIT .

Bolts of the charge air cooler with collector

Fig 1: Charge Air Cooler With Manifold Screws Loosening Sequence

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A Charge air cooler with manifold

1-7 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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Unlock the clamp (1) and engage in this position.

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Unlock charge air duct (1) and detach from the throttle valve (2).

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Unlock plug connection (1) and disconnect.
Loosen screws (2).
Thread out holder (3) and set aside.
Release the clamps (arrows).

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

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Unlock the tank vent line (1) and detach it.

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NOTE: TECHNICAL INFORMATION
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head.
Unlock the coolant line (1) and detach it.

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Release the holder (arrow).
Put coolant line (1) aside.

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

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Unlock the coolant line (1) and detach it.

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Loosen screws in the order (7) to (1).
Feed out the charge air cooler (A) and lever it toward the top.

Fig 2: Charge Air Cooler Screws Loosening Sequence
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Loosen the clamp (arrow).
Unlock plug connection (2) and disconnect.
Feed out the charge air cooler (1) and remove it.

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