Install charge air cooler
Bolts of the charge air cooler with collector
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 cooler.
NOTE:
Schematic diagram is for example purposes.
Some parts may differ in certain details.
Some parts may differ in certain details.
- Clean contact surface (1)
.
- Insert and position the charge air cooler (1) .
- Connect connectors (2)
and lock.
The connector (2) must engage audibly.
- Secure clamp (arrow).
- 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 |
- Connect and lock coolant line (1)
.
The coolant line (1) must engage audibly.
- 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.
- Position the coolant line (1) and secure the clamp (arrow).
- Connect and lock coolant line (1)
.
The coolant line (1) must engage audibly.
- Connect and lock the tank vent line (1)
.
The tank vent line (1) must engage audibly.
- Guide in the wiring harness section (1)
and install.
The locks (arrows) must engage audibly.
- 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.
- 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: Seal
Parts: Seal
- Install the seal dry without lubricant or mounting agent.
NOTE:
TECHNICAL INFORMATION
Incorrect assembly is possible. Ensure correct installation position.
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 the charge air line (1)
to the throttle valve (2)
and lock it.
The charge air line (1) must engage audibly.
- 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 |
- Tighten the screws (1) .
TIGHTENING TORQUES SPECIFICATION
| Charge air duct on spacers | ||
|---|---|---|
| M6x25 screw | tightening torque | 10 Nm |
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 MOUNT OF HOOD SEAL ON THE 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 ACTIVATING VEHICLE-SPECIFIC HIGH-VOLTAGE OR LOW-VOLTAGE VEHICLE ELECTRICAL SYSTEM .
- 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 THE LEFT AND RIGHT FRONT WHEEL ARCH TRIM .
- 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 .