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Charge air cooler

Charge air cooler

To remove


1. Remove the battery cover.


2. Remove the battery cooling pipe.

3. Remove the washer fluid filler pipe.

4. Remove the upper radiator member .

5. Remove the upper radiator cover.

6. Raise the car.

7. Remove the spoiler shield.

8. Remove the lower radiator cover.


9. Remove the hose clips on the charge air cooler hose.

Note

If the hose clips are difficult to access, undo the front bumper shell.


10. Remove the hoses from the charge air cooler.

11. Lower the car.

12. Remove the bolts from the condenser.


13. Use 83 95 212 Strap to secure the condenser and charge air cooler in the engine bay.

14. Remove the bolts on the charge air cooler.

15. Raise the car.

16. Remove the lower charge air cooler mounting and leave them hanging.


17. Remove the charge air cooler.


To fit


1. Fit the charge air cooler. Make sure the wind deflectors are positioned correctly.

2. Fit the lower charge air cooler mountings.


3. Lower the car.

4. Fit the bolts to the charge air cooler.


5. Fit the condenser and remove the strap from the condenser and charge air cooler.

6. Fit the bolts on the condenser.

7. Raise the car.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


8. Fit the hoses to the charge air cooler and tighten the hose clips.


9. Fit the lower radiator cover.

10. Fit the spoiler shield .

11. Lower the car.

12. Fit the upper radiator cover.

13. Fit the upper radiator member .

14. Fit the battery box breather pipe.


15. Fit the washer fluid filler pipe.

16. Fit the battery cover.