Intercooler: Service and Repair

Removing And Installing The Charge Air Cooler

Removing the charge air cooler.
Preliminary work: The accessories rear end bumper and the wheel housing liner must be removed.

1. Disconnect the connecting hose between the air cleaner and the charge air cooler. To do so, lever out the retaining clip on the top of the charge air cooler and pull the hose out.
2. Pull the lower connecting hose off the charge air cooler. To do so, lever the retaining clip out and pull the hose downwards.







3. Undo the front fastening. Unscrew the fastening nut and the two fastening screws.







4. Undo the bolts on the heat shield. Undo the two sheetmetal nuts on the lower end of the heat shield. Then press the heat shield out of the studs.







5. Undo the rear fastening. Unscrew the fastening nut and the fastening screw.
6. Remove charge air cooler.

Installing the charge air cooler
1. Re-install the shield of the exhaust system. Tighten the two fastening nuts on the side member for this purpose.







2. Install charge air cooler. To do so, place the charge air cooler back in the vehicle.
3. Tighten the front two fastening nuts and the fastening screw in the wheel well, all to 23 Nm (17 ftlb.)







4. Tighten the front fastening nut and the fastening screw to 23 Nm (17 ftlb.). Supply the two hose connections on the charge air cooler with new O-rings and fit them in place. The connections must audibly engage.
5. Tighten the two sheetmetal nuts on the heat shield.







Re-install the rear spoiler.