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Charge air cooler (B204R)

Charge air cooler (B204R)

To remove



1. Open the bonnet and protect the wings with drapes.

Remove the front grille.

2. Detach the washer hoses from the retaining clips in the bumper and remove the wiper arms.

3. Unplug the connectors and remove the light clusters and headlamps on both sides.

4. Remove the outside temperature sensor from the bumper's centre air intake and bend it aside.

5. Remove the heat shield over the exhaust manifold. Undo the hose clips and remove the turbo delivery hose between the turbocharger's outlet and the charge air cooler. Undo the hose clips and remove the delivery hose between the charge air cooler and turbocharger delivery pipe.


6. Raise the car. Remove the LH and RH air shields.


7. Unplug the fog light connectors.

8. Detach the front edges of the wing liners from the bumper.

9. Lower the car to a convenient working height and remove the bumper's 2 retaining bolts. Lift the bumper off by pulling it forwards.


10. Remove the charge air cooler's 2 retaining bolts and lift it out.


To fit



1. Hang the charge air cooler in place and fit the 2 bolts.

2. Position the bumper and tighten the 2 bolts.

3. Fit the outside temperature sensor in the bumper's centre air intake.


4. Carefully bend the wing liners into position on the bumper and screw them in place.

5. First attach the delivery hose to the turbocharger and charge air cooler, but do not tighten the hose clips. Then attach the delivery hose to the charge air cooler and turbocharger delivery pipe, but do not tighten the hose clips.

6. Raise the car. Check that both delivery hoses are correctly fitted. Adjust as necessary and then tighten the hose clip at the turbocharger's outlet.

7. Fit the air shields.

8. Plug in the fog light connectors.

9. Lower the car and tighten the hose clips on the turbocharger delivery hoses.


10. Fit the heat shield over the exhaust manifold.

11. Secure the washer hose in the clips on the bumper and fix it in the outlet for the wiper arm on LH and RH sides.


12. Fit the headlamps and light clusters.

13. Fit the wiper arms and front grille.