Intercooler: Description and Operation

Charge Air Cooler System Overview

• Various hose connections are secured.

• If necessary, use lubricant (water without additive) to assist assembly. Do not use lubricants containing oil.

• The charge air system must be properly sealed.

• With connector couplings, follow the installation instructions closely. Refer to => [ Hose Connections with Connector Couplings ] Service and Repair.

• The components illustrated here are for cylinder bank 2. They are a mirror image of the components for cylinder bank 1.

Follow all safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.

Note the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.






1 Air Duct

2 Bolt

• 8 Nm

3 Spacer Bushing

4 Charge Air Cooler

• Remove the bumper cover.

5 O-ring

• Replace if damaged.

6 Bolt

• 3 Nm

7 Charge Air Pressure Sensor with Intake Air Temperature Sensor

Cylinder bank 1:

• Charge air pressure sensor (G31) with intake air temperature sensor (G42).

Cylinder bank 2:

• Charge air pressure sensor 2 (G447) with intake air temperature sensor 2 (G299).

8 Charge Air Pipe

9 Retaining Clip

• Check for secure seating.

10 to the Intake Connection

• Vehicles with engine code BKW, see => [ (Item 1) Intake Connection with Intake Flap Motor ] EGR Components.

• Vehicles with engine code BWF, see => [ (Item 15) Intake Connection with Intake Flap Motor ] EGR System.

11 Connecting Hose

12 Bolt

• 8 Nm

13 from the Connecting Pipe

• See => [ (Item 11) Connecting Pipe ] Turbocharger Overview.