Audi Workshop Service and Repair Manuals

Removing and installing charge air cooler Removing   Note Check all hoses and pipes for correct fitting and leakage before carrying out tests or repairs.

–  Remove noise insulation -arrows-. –  Remove bumper cover → Rep. Gr.63. –  Remove bonnet → Chapter.

–  Take off engine cover panel -arrows-. –  Remove noise insulation located below (detach crankcase breather hose).

–  Unplug electrical connector -1- at intake manifold pressure sender -G71- and move wiring clear. –  Remove air intake hose -2- between charge air cooler and intake manifold.

–  Pull oil dipstick out of guide tube. –  Remove guide tube -1- for oil dipstick. –  Pull oil filler pipe -2- off oil filler reservoir.

–  Move oil filler neck past stop to right side of vehicle -arrow-. –  Lift off oil filler neck.

–  Unscrew bolts -arrows-. –  Remove oil filler reservoir from lock carrier.

–  Unscrew bolts -arrows- at front of lock carrier.

–  Remove intake manifold pressure sender -G71--arrow- from charge air cooler.

–  Remove bolts -3- and -4- working from reverse side of lock carrier.

–  Remove air intake hose from charge air cooler -arrow-.

–  Remove bolts -5- and -6- working from reverse side of lock carrier and remove charge air cooler. Installing Installation is carried out in the reverse order; note the following:   Note t  Charge air system must be free of leaks. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Install bumper cover → Rep. Gr.63. Tightening torques

Component	Nm
Charge air cooler to lock carrier	6
Charge air cooler to radiator	6
Guide tube for oil dipstick to oil filter bracket	10