Intercooler: Service and Repair

Charge Air Components Overview

• Various hose connections are secured.

• If necessary, use lubricant (water without additive) to assist assembly. Do not use lubricants containing oil.

• Charge air system must be properly sealed.

• With connector couplings, follow the installation instructions closely. Refer to --> [ Hose Connections with Connector Couplings ] Hose Connections with Connector Couplings.

• The components illustrated here are for cylinder bank 2. They are a mirror image of the components for cylinder bank 1.

Observe safety precautions. Refer to --> [ Safety Precautions ] Safety Precautions.

Note rules of cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.





1 Air duct

2 8 Nm

3 Spacer bushing

4 Air charge cooler

• To remove, remove bumper cover.

5 O-ring

• Replace if damaged.

6 3 Nm

7 Charge air pressure sensor with Intake Air Temperature (IAT) sensor

Cylinder bank 1:

• Charge air pressure sensor (G31) with IAT sensor (G42).

Cylinder bank 2:

• Charge air pressure sensor 2 (G447) with IAT sensor 2 (G299).

8 Charge air pipe

9 Retaining clip

• Check for secure seat.

10 To intake connection

• Vehicles with engine code BKW --> [ (Item 1) Intake connection with ] Exhaust Gas Recirculation Assembly Overview.

• Vehicles with engine code BWF --> [ (Item 15) Intake connection with ] Exhaust Gas Recirculation Assembly Overview.

11 Connecting hose

12 8 Nm

13 From connecting pipe

• --> [ (Item 11) Connecting pipe ] Turbocharger Assembly Overview.