Installing the right-hand charge air cooler

• Replace hose (1).

  Parts:  Hose

• Position hose (1) with hose clamps (2) as shown.
• 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.
• Position hose clamp (4) on hose (5) (diameter of 77-84 mm) at the bottom.

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• Ensure that the hose clamp (4) at the bottom in the area of the threaded connection is aligned with the rubber mount on the charge air cooler.
• Insert and position the charge air cooler (1).

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• Tighten snap rings (1) on charge air cooler (2).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  hose
  hose	Tightening torque	3.5 Nm

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• Tighten down screw (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Charge air cooler top
  M6x30 screw	Tightening torque	10 Nm

• Connect connectors (2) and lock.

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• Snap line (1) into holder (2).

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

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• Snap-in the holder (1) on the charge air cooler in arrow direction.

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• Carefully position the line (1) in arrow direction.
• 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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Securing tank ventilation line of cylinder bank 1 

• Position the tank vent line.
• Clip in the tank vent line in the area (2).
• Connect the tank vent line with the engine ventilation line (1) and lock it.

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• Tighten hose clamp (3).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  hose
  hose	Tightening torque	3.5 Nm

• Tighten hose clamp (4).

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  TIGHTENING TORQUE SPECIFICATIONS
  
  

  hose
  hose	Tightening torque	3.5 Nm

• Position holder (2).
• Tighten down screw (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Charge air cooler bottom
  M6x18 screw	Tightening torque	10 Nm

• Slide hose (2) onto the nozzle of the charge air cooler.
• Tighten hose clamp (1).
• Insert the hose (3) in the holder on the charge air cooler.

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• Guide hose (3) into the holder on the charge air cooler.
• Tighten hose clamp (2).
• Slide hose (1) onto the nozzle of the charge air cooler.

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• Connect and lock the coolant line (2).
• Clip the Lambda oxygen sensor of cylinder bank 2 (3) into the holder.
• Clip in the cable of the primary oxygen sensor in the areas (1).
• Connect connectors (6) and lock.
• Position coolant line (4).
• Lock holder (5).

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• Install the connecting plate (1).
• Tighten the screws (2).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Connecting plate of charge air cooler
  screw	Tightening torque	6.5 Nm

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• Position the coolant line (1) on the centering bearing (3).
• Tighten nut (2).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Coolant line to the connecting plate
  Nut M6	Tightening torque	8 Nm

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• Position the coolant ventilation line (2) in the holder (1).
• Lock holder (1).

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Follow-up work 

• Refer to CLOSING THE LOW-TEMPERATURE COOLANT CIRCUIT .
• Refer to INSTALLING FRONT UNDERBODY PROTECTION .
• Refer to INSTALLING THE LOWER LEFT FRONT WHEEL ARCH COVER .
• Refer to INSTALLING FAN COWL .
• Refer to INSTALLING THE RIGHT UNFILTERED-AIR DUCT .
• Refer to INSTALLING OIL FILLER NECK .
• Refer to INSTALLING RIGHT INTAKE SILENCER HOUSING .
• Refer to INSTALLING THE LEFT UNFILTERED-AIR DUCT .
• Refer to INSTALLING LEFT INTAKE SILENCER HOUSING .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING THE FRONT-END STRUT .
• Refer to INSTALLING UPPER CROSS CONNECTION .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT and INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE TOP RIGHT .
• Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .