Charge Air Cooler Assembly Overview
Charge Air Cooler Assembly Overview
• Before testing or performing a repair, check all air guide pipes and hoses and all vacuum lines for leaks and secure seating.
• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps appropriate for the model. Refer to the electronic parts catalog ETKA.
• In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.
1 Air Guide Hose
2 Sleeve
3 Bolt
• 9 Nm
4 Left Air Guide Pipe
5 Gasket
6 Air Guide Hose
• Removing
• Installing
7 Charge Air Cooler
• Removing and installing, refer to => [ Charge Air Cooler ] Charge Air Cooler
8 Gasket
9 Mount
10 Bolt
• 5 Nm
11 Mount
12 Air Guide Hose
• Removing
• Installing
13 Air Guide Hose
14 Air Guide Pipe
15 O-ring
• Replace
16 Charge Air Pressure Sensor (G31)/Intake Air Temperature (IAT) Sensor (G42)
• Removing and installing, refer to => [ Charge Air Pressure Sensor and Intake Air Temperature Sensor ] Charge Air Pressure Sensor and Intake Air Temperature Sensor
17 Bolt
• 5 Nm
18 Bolt
• 9 Nm
19 Sleeve
20 Grommet
• Replace if damaged
21 Grommet
• Replace if damaged
Removing the Air Guide Pipes/Hoses Together with the Coupling
- Pull the clip - 1 - to unlock the coupling.
- Separate the air guide pipe/hose - 2 - by hand. Do not use any tools - arrow -.
Install the Air Guide Hoses with the Coupling
• Replace the sealing ring if it is damaged.
• Make sure the sealing ring sits completely in the groove all around the air guide pipe/hose.
• Coat the sealing surface and the sealing ring with silicone-free lubricant.
- Pull the securing clip into the release position - 1 -.
- Insert the air guide pipe/hose as far as the stop and press the securing clip into the locked position - 2 -.
- Press the air guide pipe/hose on and pull on it to make sure the connection is engaged correctly.