Intercooler: Service and Repair

WM 214319 Removing and installing charge air cooler

Technical values





Preliminary work

1. Remove the front apron. -> 631519 Removing and installing front apron - section on "Removing" .
2. Remove front wheel housing liner. -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
3. Remove front cover (engine compartment). -> 700219 Removing and installing front cover (engine compartment) - section on "Removing"

Removing charge air cooler





Installation position of charge air cooler

Unless specified otherwise, removal and installation is the same on both sides.
1. Remove suction hose.





Removing suction hose

1.1. Remove foam part -1-.
1.2. Remove suction hose -2- by turning and pulling it.
2. Remove charge air line on air box for throttle housing (Y-shaped pipe).
2.1. Open hose clamp -1- and slide it back.





Removing charge air line

2.2. Unclip vacuum hose from the two clips under the charge air line.
2.3. Remove circlip -2- on holder -4- for charge air hose -3- and slide charge air hose backwards out of the bracket.
2.4. Right side only: Remove hose -1- at the charge air line by pressing the circlip together at the sides -A- and pull off the hose -1- ( -B- ).





Hose on right charge air line

3. Remove pressure pipe.
3.1. Raise the vehicle.
-> 4X00IN Lifting the vehicle Service and Repair
3.2. Lever out wire clip -1- using a screwdriver and pull the pressure pipe -3- off the charge air cooler -2-.





Removing pressure pipe

3.3. Put wire clip -1- back into installation position immediately.
4. Remove charge air cooler.
4.1. Unscrew three fastening screws -1-.





Removing charge air cooler

4.2. Pull charge air cooler and charge air line outwards -arrow-.

Installing charge air cooler

1. Install charge air cooler.
1.1. Guide charge air cooler and charge air line inwards from the outside -arrow-.





Installing charge air cooler

1.2. Tighten three fastening screws -1- to => Tightening torque: 7 Nm (5 ftlb.).
2. Install pressure pipe.
2.1. Push pressure pipe -3- into the connection piece on the charge air cooler -2- until it clicks into place.





Installing pressure pipe

2.2. Lower the vehicle.
3. Install charge air line.
3.1. Push charge air line -3- onto the holder -4- and slide it into the air box for throttle housing (Y-shaped pipe).





Removing charge air line

3.2. Fit circlip -2- for holder.
3.3. Tighten hose clamp -1-.
3.4. Clip vacuum hose into the two clips under the charge air line.
3.5. Right side only: Push hose -1- onto the connection piece for the charge air line -2-.





Installing hose on charge air line

Replacing charge air cooler

1. Remove accessories.
1.1. Unscrew fastening screws -1- for the charge air line -2- at the charge air cooler -3-.





Charge air line on charge air cooler

1.2. At the rear air guide -1- , unclip the side locking mechanisms -2- and pull out the air guide.





Removing rear trim panel on charge air cooler

1.3. At the front air guide -2- , unclip the side locking mechanisms -1- and pull out the air guide.





Removing front trim panel on charge air cooler

2. The accessories are installed in reverse order to removal.
2.1. Tighten fastening screws on the intake manifold to => Tightening torque: 5.5 Nm (4 ftlb.).

Subsequent work

1. Install front apron. -> 631519 Removing and installing front apron - section on "Installing"
2. Install front wheel housing liner. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
3. Install front cover (engine compartment). -> 700219 Removing and installing front cover (engine compartment) - section on "Installing"