Charge Air Cooler

Charge air cooler
To remove
1. Remove the battery cover.





2. Remove the battery cooling pipe.
3. Remove the washer fluid filler pipe.
4. Remove the upper radiator member.
5. Remove the upper radiator cover.
6. Raise the car.
7. Remove the spoiler shield.
8. Remove the lower radiator cover.





9. Remove the hose clips on the charge air cooler hose.

Note: If the hose clips are difficult to access, undo the front bumper shell.

10. Remove the hoses from the charge air cooler.
11. Lower the car.
12. Remove the bolts from the condenser.





13. Use 83 95 212 Strap to secure the condenser and charge air cooler in the engine bay.
14. Remove the bolts on the charge air cooler.
15. Raise the car.
16. Remove the lower charge air cooler mounting and leave them hanging.





17. Remove the charge air cooler.

To fit
1. Fit the charge air cooler. Make sure the wind deflectors are positioned correctly.
2. Fit the lower charge air cooler mountings.





3. Lower the car.
4. Fit the bolts to the charge air cooler.





5. Fit the condenser and remove the strap from the condenser and charge air cooler.
6. Fit the bolts on the condenser.
7. Raise the car.

Important: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 30 15 815 Cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.

8. Fit the hoses to the charge air cooler and tighten the hose clips.





9. Fit the lower red later cover.
10. Fit the spoiler shield.
11. Lower the car.
12. Fit the upper radiator cover.
13. Fit the upper radiator member.
14. Fit the battery box breather pipe.





15. Fit the washer fluid filler pipe.
16. Fit the battery cover.