Intercooler: Service and Repair

Charge Air System Components Overview

• All hose connections for the charge air system are secured by spring type clamps or by connector couplings. Be sure to follow the assembly guidelines when installing the connectors. Refer to one of the following: => [ Charge Air Hose Connections, with Connector Couplings ] Charge Air Hose Connections, With Connector Couplings or to => [ Charge Air Hose Connections, with Threaded Connections ] Charge Air Hose Connections, With Threaded Connections.

• The charge air system must be properly sealed.

• Checking the charge air system for leaks. Refer to => [ Charge Air System, Checking for Leaks ] Charge Air System, Checking For Leaks.


The clamps for the charge air hoses must be tightened to 5.5 Nm. An insufficient or excessive tightening torque can cause the charge air hose to come off the charge air pipe while driving.






1 Bolt

• 5 Nm

2 Mount

• For the charge air cooler.

3 Charge Air Cooler

• To remove, bring the lock carrier into the service position. Procedures

4 Charge Air Hose

• Cold side, bottom.

5 Screw Clamp

• 5.5 Nm

6 to the Throttle Valve Control Module

7 Charge Air Hose

• Cold side, top

8 Charge Air Pressure Sensor (G31) with Intake Air Temperature Sensor (G42)

9 Bolt

• 2 Nm

10 Rubber Grommet

• Replace if damaged.

11 Bolt

• 8 Nm

12 Charge Air Pipe

• Cold side.

13 Charge Air Hose

• Hot side, top.

14 from the Turbocharger

15 Charge Air Pipe

• Hot side.

16 Charge Air Hose

• Hot side, bottom.