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Charge air cooler

Charge air cooler

To remove


1. Remove the Front bumper shell .

2. Remove the battery cover.


3. Remove the washer fluid filler pipe.

4. Disconnect the A/C pipe from the radiator member.


5. Remove the turbocharger valve.

6. Remove the right-hand headlight.


Warning

Ensure that you do not place the top radiator bracket on the battery positive terminal, otherwise there is a risk of short-circuit/fire.


7. Remove the upper radiator member.


8. Raise the car.

9. Remove the hose clips from the charge air cooler hoses and disconnect the hoses from the charge air cooler.


10. Lower the car.

11. Remove the bolts from the condenser.


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

13. Remove the bolts on the charge air cooler.

14. Raise the car.

15. Remove the lower charge air cooler mountings.


16. Remove the charge air cooler.


To fit


1. Fit the charge air cooler.

2. Fit the lower charge air cooler mountings.


3. Lower the car.

4. Fit the bolts on 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 spoiler shield .

10. Lower the car.

11. Fit the upper radiator cover.

12. Fit the upper radiator crossmember


13. Fit the A/C pipe to the radiator member and the turbocharger valve.


14. Fit the washer fluid filler pipe.


15. Fit the battery cover.

16. Fit the right-hand headlight.


17. Fit the Front bumper shell .