Removing and installing charge air cooler

Special tools and workshop equipment required

Hose clamps up to 25 mm -3094-

Drip tray for workshop hoist -VAS 6208-

Hose clip pliers -VAS 6362-

Removing

• Remove radiator cowl → Chapter.

• Open clip -1- and push hose -arrow- to one side.
• Disconnect connector -1-.

• Remove air conditioner compressor from bracket -arrows- and tie it up → Air conditioner compressor; Removing and installing air conditioner compressor from and to bracket; Rep. gr.87.
• Set drip tray for workshop hoist -VAS 6208- underneath.
• Clamp off coolant hoses at charge air cooler with hose clamps -3094-.

• Release hose clips -1- and detach coolant hoses.
• Remove bolts -arrows-.

• Pull charge air cooler -1- evenly towards front (in -direction of arrow-) out of intake manifold.

Installing

Installation is carried out in the reverse order; note the following:

• Fit sealing lip -1- in -direction of arrow- onto charge air cooler -2-.
• Insert new gasket into groove on intake manifold.

• Tighten bolts -arrows- alternately and diagonally working from centre outwards.
• Install hose clips -1-.

Note

If there are minor dents in the fins, refer to → Chapter.

• Install radiator cowl → Chapter.
• Check coolant level → Anchor.

Specified torques

→ Chapter „Assembly overview - charge air system“

→ Heating, air conditioning system; Rep. gr.87