2.0 TFSI engines
1. The intercooler installation details are shown in the illustration.
6.1. Intercooler installation details1. Intercooler air duct; 2. Air hose to turbocharger; 3. Clamps, 5.5 Nm; 4. Air hose to intake manifold; 5. Gasket; 6. Sealing ring (only on the left intercooler), subject to replacement; 7. Boost pressure sensor (only on the left intercooler); 8. Bolt (only on the left intercooler), 5 Nm; 9. Supports; 10. Intercooler bracket; 11. Rubber gasket; 12. Support mounting bolts, 22 Nm; 13. Intercooler; 14. Refrigerant line bracket; 15. Bolt, 15 Nm
2. On models with independent/additional heating, unscrew the bolts (arrows in illustration 5.4 Chapter 2) its exhaust pipe from the soundproofing screen.
3. Release the fasteners (1 and 2 in Illustration 5.5 Chapter 2) and remove the front sound insulation. If there is rear sound insulation, release the clips (3) and remove it.
4. Remove the front bumper cover (see Chapter 11) and both headlights (see Chapter 12).
5. Remove the air ducts of both intercoolers (see illustration 17.2 Chapter 2).
6. Disconnect the connector (3 in the illustration) boost pressure sensor and release the coolant line (4) from the bracket without disconnecting it. Loosen the clamps (1 and 2), disconnect the hoses and remove the intercooler by pulling it upwards.
6.6. Removing the intercooler
7. Installation is carried out in the reverse order of dismantling the components.
Engines 1.8 l
8. The details of the intercooler installation are shown in Figure 6.1.
9. Move the hood lock holder to the service position (see Chapter 2).
10. Loosen the clamps (1 and 2 in Illustration 6.6) and disconnect the hoses. Disconnect the coolant line (4) from the bracket, disconnect the boost pressure sensor/IAT sensor connector (3) and remove the intercooler by moving it upwards.
11. Installation is carried out in the reverse order of dismantling the components.
4-cylinder diesel engines
12. The intercooler installation details are shown in the illustration.
6.12. SOHC models intercooler installation details (DOHC - similar)1. Intercooler air duct; 2. Air hose to the hood lock holder; 3. Air hose to air tube; 4. Sealing ring; 5. Intercooler; 6. Supports; 7. Intercooler bracket; 8. Rubber gasket; 9. Refrigerant line bracket; 10. Bolt, 10 Nm
13. Removal and installation of the intercooler is carried out in the same way as for petrol models (see above).