Intercooler — removal and installation (Audi A4 B5)

Table of contents: Removal ↓ Installation ↓

Note: This paragraph applies to AEB and AJL engines only.

Removal

1. Apply the handbrake, raise the front of the car and install safety stands (see Jacking up a car and installing safety supports). Remove the lower engine cover.

2. The intercooler is installed on the left side of the engine compartment. It can be accessed after removing the front panel of the body, but without disconnecting the radiator hoses or electrical wiring. To do this, first remove the front bumper - see chapter 11. Unscrew the three quick-release clips from the noise-insulating panel, remove the air duct between the front panel of the body and the air filter. To the left of the radiator, release the wiring from its fasteners. Unscrew the bolts securing the front panel to the side members of the body, unscrew the upper side bolts located behind the headlights. Together with an assistant, move the front panel away from the body as far as possible. Audi mechanics use special brackets to fix the panel in this position, but they can be made from pieces of rod, cutting threads on them and screwing them into the side members.

3. Loosen the clamp and disconnect the upper hose from the intercooler.

4. Remove the air duct from the front of the intercooler. Remove the rubber seals.

5. Loosen the clamp and disconnect the lower hose from the intercooler.

6. Remove the lower part of the intercooler from the mounting seal and unhook it from the upper mounting seals. Remove the intercooler from the car downwards. If necessary, remove the seals from the mounting brackets.