Removing and installing charge air cooler

Special tools and workshop equipment required

• Hose clamps to 25 mm - 3094-

• Drip tray for workshop hoist - VAS 6208-

• Spring-type clip pliers - VAS 6362-

Removing

• Observe rules for cleanliness ⇒ 1.1 Safety regulations for working on fuel supply.
• Remove air filter ⇒ 3.2 Removing and installing air filter housing.
• Remove radiator cowl ⇒ 4.5 Removing and installing radiator cowl with radiator fan.

• Place drip tray for workshop hoist - VAS 6208- underneath.

• Clamp off coolant hoses -1- on charge air cooler using hose clamps, up to Ø 25 mm - 3094-.
• Release hose clip -1- and remove coolant hose.
• Unscrew bolts -arrows-.

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

Installing

Install in reverse order of removal. The following should be observed:

• 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-.
• Install radiator cowl ⇒ 4.5 Removing and installing radiator cowl with radiator fan.
• Check coolant level ⇒ 1.3 Draining and adding coolant.

Torque settings

• ⇒ 4.1 Assembly overview - radiator/radiator fan
• ⇒ 2.1 Assembly overview - charge air system
• ⇒ 3.1 Assembly overview - air filter housing