Intercooler: Service and Repair

Removing And Installing The Charge Air Cooler

Preliminary work
1. Remove the front spoiler.

Removing the charge air cooler

WARNING:
Airbag could inflate when airbag sensor is pulled off.
- The cable connector for the airbag sensor remains connected. Only the cable from the sheetmetal clip to the air guide is removed.

1. Release airbag sensor cable from sheetmetal clip. Leave cable plug on the airbag sensor.

2. Pull air guide in front of charge air cooler off to the side.

3. Disconnect lower pressure pipe. To do so, lever out wire clips using a screwdriver -1- and pull off tube. Put wire clips back into installation position immediately.

4. Unscrew the two hexagon socket head bolts (M6 x 20) on the pressure pipe -arrows- and pull off pressure pipe.

5. Pull off air guide to air cleaner housing.

6. Unscrew the three fastening screws on the charge air cooler -arrows-, press the charge air cooler carefully towards the tyres and remove sideways.

Installing the charge air cooler

NOTE: Always replace all seals and sealing rings.

1. Move the charge air cooler sideways into installation position and insert the three fastening screws -arrows- by hand.

2. Press air line into air cleaner housing. This must engage audibly.

3. Push the pressure pipe with the new sealing ring into the flange of the charge air cooler and place two hexagon socket head bolts on the air pipe -arrow-. Tighten the screws. Tightening torque: 7.5 ftlb.

4. Tighten the three fastening screws of the charge air cooler. Tightening torque: 6 ftlb.
5. Special Turbo "Kit" and Turbo "S": When assembling, also make sure that the assembly markings -D- and the sealing rings -A- are in the correct position. Fit the V-band clamp correctly on the connecting points.

6. Insert lower pressure pipe. Wire clip must engage audibly -1-.

7. Push in air guide laterally in front of charge air cooler.

8. Place airbag sensor cable into the sheetmetal clip.

Subsequent work
1. Install front apron.