Installing the charge air cooler

Fig 1: Installation position for V8 Turbo charge air cooler

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NOTE:

Always replace all seals and sealing rings!

Fig 2: Fastening screws on the charge air cooler

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1. Move the charge air cooler sideways into installation position and insert the three fastening screws -arrows- by hand. See Fig 2.

Fig 3: Charge-air cooler air guide

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2. Press air line into air cleaner housing. This must engage audibly.

Fig 4: Mount for pressure pipe

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3. Push the pressure pipe with the new sealing ring into the flange of the charge air cooler and place two hexagon socket head bolts on the air pipe -arrow- . Tighten the screws. → Tightening torque: 7.5 ftlb. See Fig 4.

4. Tighten the three fastening screws of the charge air cooler. → Tightening torque: 6 ftlb.

Fig 5: Positioning the sealing ring between charge air cooler and pressure pipe

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5. Special Turbo "Kit" and Turbo "S": When assembling, also make sure that the assembly markings -D- and the sealing rings -A- are in the correct position. Fit the V-band clamp correctly on the connecting points. See Fig 5.

Fig 6: Lower pressure pipe

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6. Insert lower pressure pipe. Wire clip must engage audibly -1- . See Fig 6.

Fig 7: Air guide

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7. Push in air guide laterally in front of charge air cooler.

Fig 8: Cable for airbag sensor

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8. Place airbag sensor cable into the sheetmetal clip.