Withdrawal
All cars
1. Remove the engine top cover.
2. Remove the inlet hose, outlet hose and charge air cooler clamps. Discard hoses and clamps as they are no longer needed.
Vehicles manufactured up to 04.2000
3. Remove the inlet and outlet pipes of the charge air cooler. Discard pipelines as they are no longer needed.
Vehicles manufactured since 04.2000
4. Remove the intake and exhaust pipes of the charge air cooler.
Attach the lower suspension arm (right side shown).
5. Disconnect the positive crankcase ventilation hoses (PVC) from the valve cover.
Common Rail Fuel Injection Vehicles
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. Coat the valve cover gasket with clean engine oil before installing it.
Common Rail Fuel Injection Vehicles
2. Connect the plug connector of the camshaft position sensor (CMP).
All cars
3. Connect the positive crankcase ventilation hoses to the valve cover.
Vehicles 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.
Vehicles manufactured up to 04.2000
6.
NOTE: Install new charge air cooler intake and exhaust pipes.
Install the charge air cooler intake and exhaust pipes.
Vehicles manufactured since 04.2000
7. Install the charge air cooler inlet and outlet pipes.
All cars
8.
NOTE: Set the worm-drive clamps to the position «8 ocloc'k» when viewed from the front of the car.
NOTE: Install new inlet hose, outlet hose and charge air cooler clamps.
Install the intake hose, exhaust hose and charge air cooler clamps.
9. Install the engine top cover.
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