Contents: Removal ↳ Installation ↳
Removal
All cars
1. Remove the top engine cover.
2. Remove the charge air cooler inlet hose, outlet hose and clamps. Discard the hoses and clamps as they are no longer needed.
Cars manufactured up to 04.2000.
3. Remove the charge air cooler inlet and outlet pipes. Discard the pipes as they are no longer needed.
Cars manufactured since 04.2000.
4. Remove the charge air cooler inlet and outlet pipes.
Secure the lower control arm (right side shown).
5. Disconnect the positive crankcase ventilation (PVC) hoses from the valve cover.
Vehicles with common rail fuel injection systems
6. Disconnect the camshaft position sensor connector.
All cars
7. Remove the cylinder head cover.
Installation
All cars
1.
NOTE: Install a new valve cover gasket if necessary.
Install the valve cover. Apply clean engine oil to the valve cover gasket before installing it.
Vehicles with common rail fuel injection systems
2. Connect the camshaft position (CMP) sensor connector.
All cars
3. Connect the positive crankcase ventilation hoses to the valve cover.
Cars manufactured up to 05.1999.
4.
NOTE: Install a new charge air cooler resonator.
Install the charge air cooler resonator.
5.
NOTE: Install a new charge air cooler resonator hose.
Install the charge air cooler resonator hose.
Cars manufactured up to 04.2000.
6.
NOTE: Install new charge air cooler inlet and outlet pipes.
Install the charge air cooler inlet and outlet pipes.
Cars manufactured since 04.2000.
7. Install the charge air cooler inlet and outlet pipes.
All cars
8.
NOTE: Install the worm drive clamps to the 8 o'clock position when viewed from the front of the vehicle.
NOTE: Install a new charge air cooler inlet hose, outlet hose and clamps.
Install the charge air cooler inlet hose, outlet hose and clamps.
9. Install the top engine cover.
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