Installing Charge Air Cooler

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Moulded hose on charge-air cooler

Undo screw-type clamps -2-  and remove moulded hose -1-  .

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Pressure pipe

Release and disconnect plug-coupling -5-  and move vacuum line -1-  aside.

Release and disconnect plug-coupling -6-  and move positive crankcase ventilation line -2-  aside.

Close off line connections using suitable stoppers.

Unclip clip -7-  .

Release and disconnect electric plug connections -3-  and move electric line -8-  aside.

Information 

The central support sleeve cannot be removed without being destroyed and must be replaced following removal.

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Charge air cooler

Loosen screw-type clamp -2-  .

Drill out head of support sleeve -3-  using a drill bit (approx. 10 mm in diameter) and push support sleeve -3-  forwards through the bracket.

Unscrew and remove screws -4-  .

Remove charge-air cooler -1-  .

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Charge air cooler

Position charge-air cooler -1-  .

Insert new  support sleeve -3-  .

Screw in and tighten new  screws -4-  .

> Tightening torque 10 Nm (7.5 ftlb.) 

Tighten screw-type clamp -2-  .

> Tightening torque 5.5 Nm (4 ftlb.) +/- 0.5 Nm (0.35 ftlb.) 

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Pressure pipe

Position electric line -8-  , then push on and lock electric plug connections -3-  .

Clip in clip -7-  .

Position positive crankcase ventilation line -2-  and push plug-in coupling -6-  onto pressure pipe -4-  .

Position vacuum line -1-  and push plug-in coupling -5-  onto pressure pipe -4-  .

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Moulded hose on charge-air cooler

Coat the inside of the moulded hose -1-  with Kluberplus gel  .

Position the -1-  moulded hose.

Tighten screw-type clamps -2-  .

> Tightening torque 5.5 Nm (4 ftlb.) +/- 0.5 Nm (0.3 ftlb.)