Install charge air cooler

Bolts of the charge air cooler with collector

Fig 1: Charge Air Cooler Bolts Tightening Sequence

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NOTE: RISK OF DAMAGE
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.

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

Replace the seals (1) .
Parts: Seals

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Check the rubber mount (1) for a correct fit on the charge air cooler.

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NOTE: Schematic diagram is for example purposes.
Some parts may differ in certain details.

Clean contact surface (1) .

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Ensure that charge air cooler (1) fits correctly on the bottom holder (2) during installation.

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Insert and position the charge air cooler (A) .
Tighten the screws in the sequence (1) to (7) .

TIGHTENING TORQUE SPECIFICATIONS

Charge air cooler on cylinder head
M6	tightening torque	10 Nm

Fig 2: Charge Air Cooler Screws Tightening Sequence

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Secure clamps (1) to charge air cooler (2) in the marked area.

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Connect connector (1) to throttle valve (2) and lock it.
The connector (1) must engage audibly.

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Connect and lock the tank vent line (2) .
The tank vent line (2) must engage audibly.
Connect and lock the coolant lines (1) .
The coolant lines (1) must engage audibly.

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Connect and lock coolant line (1) .
The coolant line (1) must engage audibly.

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Connect and lock coolant line (1) .
The coolant line (1) must engage audibly.

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Insert and install the holder (2) .
Tighten the screws (1) .

TIGHTENING TORQUE SPECIFICATIONS

Holder to charge air cooler
6x18 screw	Tightening torque	5.5 Nm

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Secure clamps (2) .
Connect connectors (1) and lock.

The connector (1) must engage audibly.

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Secure the clamp (1) .

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Guide the tank vent line (3) into the holders (2) and connect it to the charge air cooler.
Tighten nut (1) .

TIGHTENING TORQUE SPECIFICATIONS

Tank vent line to charge air cooler
Nut	Tightening torque	4 Nm

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Insert and install the wiring harness section (2) .
The lock (1) must engage audibly.

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Secure the tank ventilation line (1) to the clamp (2) .

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Connect the tank vent line to pressure sensor (3) .
Ensure that all locks (2) engage audibly.
Connect connectors (1) and lock.
The connector (1) must engage audibly.

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Guide in the wiring harness section (1) and install.
The locks (arrows) must engage audibly.

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Ensure that the guide sleeves (1) are present and have been installed correctly.

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Ensure that the guide sleeves (1) are present and have been installed correctly.

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Check seal (1) for damage, replace if necessary.

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Replacing the damaged seal

NOTE: TECHNICAL INFORMATION
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.

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Replace gasket.
Parts: Gasket
Install the seal dry without lubricant or mounting agent.

NOTE: TECHNICAL INFORMATION
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.

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Lock clamp (1) .

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Connect and lock charge air hose (2) .
The clamp (1) must engage audibly.

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Connect connectors (1) and lock.
The connector (1) must engage audibly.

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Attach holder (1) to the electrical auxiliary coolant pump (2) .

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Feed in and install the electrical auxiliary coolant pump (2) .
Tighten nut (1) .

TIGHTENING TORQUE SPECIFICATIONS

Electric coolant pump to holder
M6	tightening torque	8 Nm

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Insert the charge air crossing (2) and position it.
Tighten the screws (1) .

TIGHTENING TORQUE SPECIFICATIONS

Charge air duct on spacers
M6x25 screw	tightening torque	10 Nm

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Tighten the screws (1) .

TIGHTENING TORQUE SPECIFICATIONS

Charge air duct on spacers
M6x25 screw	tightening torque	10 Nm

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Follow-up work

Refer to INSTALLING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to CONNECTING THE COOLANT LINES FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to SECURING THE ENGINE OIL COOLER .
Refer to INSTALLING FAN COWL .
Refer to CONNECTING THE COOLANT LINE TO THE RADIATOR .
Refer to INSTALLING THE RIGHT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING UPPER CROSS CONNECTION .
Refer to INSTALLING THE CENTER ENGINE COMPARTMENT COVER .
Refer to INSTALLING THE FRONT HOOD SEAL .
Refer to INSTALLING THE INTAKE FILTER HOUSING ON THE LEFT (FRONT-END STRUT REMOVED) .
Refer to INSTALLING THE CLEAN AIR PIPE FOR CYLINDERS 1 TO 3 .
Refer to INSTALLING THE CONTROL UNIT HOLDER .
Refer to PARTIALLY INSTALLING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
Refer to INSTALLING THE DME CONTROL UNIT .
Refer to INSTALLING THE COVER FOR THE DME CONTROL UNIT .
Refer to INSTALLING ACOUSTIC COVER .
Refer to INSTALLING THE STRUT BRACE .
Refer to INSTALLING THE FRONT-END STRUT .
Refer to ACTIVATING THE 48 V ELECTRICAL SYSTEM .
Refer to FILLING AND VENTING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to INSTALLING THE STIFFENING PLATE .
Refer to INSTALLING THE LEFT AND RIGHT FRONT UNDERSHIELD .
Refer to INSTALLING THE BOTTOM FRONT RIGHT SIDE COVER .
Refer to INSTALLING BOTTOM FRONT COVER FROM THE SIDE .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to INSTALLING THE FRONT SPOILER .