Intercooler: Service and Repair
Charge air cooler, 4-cyl.To remove
1. Remove the radiator, 4-cyl.
2. Raise the car.
3. Remove the charge air cooler's bracket from the oil cooler.
4. Suspend the oil cooler from the charge air cooler's bracket by means of cable ties.
5. Lower the car to the floor.
6. Undo the hose clips on the charge air cooler's inlet and outlet connections. Remove the hoses. Remove the fasteners securing the charge air cooler to the body.
7. Remove the front grille.
8. Remove the headlamps and direction indicators and set aside.
9. Suspend the capacitor with a cable tie, part No. 83 95 212.
10. Remove the charge air cooler's bracket from the condenser.
11. Lift out the charge air cooler.
To fit
Note: Spray the connector with Kontakt 61 contact cleaner, part No. 30 04 520.
Fit in the reverse order. See the tightening torques specified below for direction indicators without screw slots. Check the headlamp alignment.
Tightening torques:
Charge air cooler/condenser 8 Nm (6 ft. lbs.)
Screw for direction indicator, hole fitting 1.5 Nm (1 ft. lbs.)